Modular connectors as a key component for the All Electric Society
As renewable energy and digital technologies grow, demands on electrical connections continue to rise. Innovative high‑current solutions, such as modular connectors, offer a powerful and flexible alternative to traditional systems.
The All Electric Society envisions a future powered almost entirely by renewable, carbon‑neutral energy. As a result, electricity demand is rising across both AC and DC systems, requiring not only increased power generation but also efficient distribution and storage. High‑current solutions are key to building high‑performance infrastructure in industry, mobility, and power supply.
The expansion of renewable energy brings new challenges: solar and wind systems feed high currents into the grid, while battery storage is needed to buffer and supply energy on demand. At the same time, power‑to‑X and digitalization are driving electricity demand, particularly for AI and cloud services. As a result, connectors are becoming critical interfaces for reliable power and data transmission.
Additionally, connector requirements for high‑current applications are steadily rising. They must handle high currents safely and reliably while supporting miniaturization, effective thermal management, electromechanical compatibility, and data integrity.
Areas of application for high-current connectors
The latest high‑current applications place diverse demands on power distribution and transmission, which are reflected in connector requirements and vary by application.
Renewable power generation and distribution:
Solar and wind systems feed high currents into the grid (e.g., up to 42 A from a 10 kW PV system), requiring connectors suitable for both DC and AC use while meeting strict environmental, insulation, and touch‑protection requirements.
Battery storage systems:
Moreover, stationary and mobile batteries buffer renewable energy and supply it as needed. Their connectors must safely handle high charge and discharge currents with low contact resistance and strong thermal stability to minimize losses.
Power‑to‑X:
Power‑to‑X technologies convert electricity into hydrogen, methane, or heat and involve complex, safety‑critical processes. Connectors must withstand high continuous currents and be mechanically robust, vibration‑, corrosion‑, and temperature‑resistant, with secure locking and touch protection.
Data centers:
Driven by cloud computing and AI, data centers are major and rapidly growing energy consumers, with demand expected to double within five years. Modular designs increase the need for connectors in power‑intensive areas such as cooling, HVAC, emergency power, and PDUs, which distribute electricity to servers and network equipment.
To meet these demands, connectors must maximize current per conductor and support heavy cables. High‑performance connectors offer significant advantages over conventional CEE systems, requiring far less space, carrying higher currents, and reducing power losses and cooling needs.
Limits of traditional connectors
Connector requirements vary by application, but many share needs that traditional solutions like CEE connectors no longer meet. Their bulky design and limited flexibility make them unsuitable for growing high‑energy and high‑current applications, highlighting the need for new connector concepts for future use.
Rising current peaks in high‑energy applications show that connector requirements are increasing rapidly. Future‑proof high‑current connectors must support this growth. Phoenix Contact’s Heavycon Modular system addresses this need by allowing custom combinations of power, data, and signal modules for application‑specific solutions.
Data modules:
Modules such as Mbit, Gigabit, USB, and RJ45 support reliable data transmission in industrial applications including image processing, robotics, machine control, cloud services, and communication between servers, workstations, and storage systems.
Signal modules: Robust signal modules enable dependable communication with sensors and actuators, even in harsh industrial environments.
Power modules up to 300 A
The key innovation lies in the power modules. While traditional CEE plugs support up to 125 A, Phoenix Contact’s new power modules deliver up to 300 A in a compact design.
Single push‑in modules carry up to 76 A, single crimp modules up to 100 A, and double crimp modules up to 300 A. Tool‑free mounting and removal of modules and cables, secure spring fixing, and convenient push‑in wiring ensure easy, vibration‑resistant installation.
Learn more about the HEAVYCON.
