Pune, India | September 08, 2025
A newly introduced high-efficiency contactor addresses a key challenge in the electric vehicle (EV) industry: the mismatch between 400-volt and 800-volt charging systems. While 800V platforms offer faster charging and better power efficiency, most public chargers still operate at 400V. This new contactor bridges the gap. It allows EVs to switch smoothly between both voltages, removing the need for bulky and expensive boost converters.
This advancement simplifies EV electrical systems without sacrificing safety or performance. It supports dynamic battery reconfiguration, so a vehicle can operate across both voltage systems. With this solution, 800V EVs can use 400V charging stations without additional hardware. This flexibility benefits manufacturers and drivers alike by lowering complexity, cutting development costs, and speeding time-to-market.
One of the key innovations is a patent-pending mechanical synchronization system. Unlike traditional designs that rely mostly on software, this contactor uses three mechanically linked high-voltage poles. This ensures synchronized operation across all poles. The design reduces risks from software errors, welded contacts, or vibration-induced faults, which improves overall safety and reliability.
Beyond voltage compatibility, the contactor enhances energy management. It allows independent control of two 400V battery packs. This enables real-time load balancing, improving efficiency and extending battery life. In case one pack fails, the system enters limp mode and runs on the other. This built-in redundancy boosts driver confidence and increases system dependability.
The contactor uses a bi-stable design, meaning it holds its position without consuming power. Its contact resistance is less than 50 micro-ohms, minimizing heat generation and energy loss. Rated for over 1,000 amps, it is well-suited for high-performance EVs and commercial vehicles with demanding power needs.
Despite its high capacity, the unit is compact and requires no active cooling. It can endure short circuits of up to 25,000 amps and withstand mechanical shocks exceeding 90g—crucial for tough automotive environments. It also reduces the component count by more than 50%, making integration easier while saving both space and weight. These gains help maximize vehicle range.
To support advanced diagnostics and safety, the contactor includes a position sensor rated to ASIL-D (Automotive Safety Integrity Level D). This sensor provides continuous feedback to onboard systems and enables real-time fault detection. Predictive maintenance becomes possible, which lowers the risk of major failures and reduces downtime.
Looking ahead, the contactor is designed for evolving EV technologies. It supports megawatt charging for heavy-duty vehicles and is ready for vehicle-to-grid (V2G) functionality. The device also aligns with the latest North American charging standards. Its adaptable architecture ensures it will stay relevant as EV infrastructure evolves.
By removing the need for voltage converters, the contactor streamlines vehicle design. It enables native compatibility with both 400V and 800V charging networks. Far more than just a switching unit, it serves as a multifunctional powertrain component with integrated battery control, fail-safe modes, and diagnostics.
As EV adoption accelerates, the supporting components must also advance. High-efficiency contactors like this one make EVs more practical, safer, and easier to integrate with current infrastructure. It’s a strong step forward toward high-performance, future-ready electric mobility.
