High-Voltage DC Relay: The Safety Guardian for New Energy Vehicles And Charging Stations

As new energy vehicles evolve toward 800V or even higher voltage platforms, charging efficiency achieves a qualitative leap. Fast charging can replenish 80% of battery capacity within 10-20 minutes, approaching the refueling experience of gasoline vehicles. However, behind this doubling of voltage lie multiple severe challenges for electrical systems: arc temperatures exceeding 3000°C during disconnection, exponentially increased insulation failure risks, and significantly heightened welding hazards from high currents. Traditional 400V system relays can no longer meet safety redundancy requirements. As the “final safety gate” in high-voltage circuits, the technical sophistication of high-voltage DC relays directly defines the safety boundaries for both vehicles and charging stations, making them a core bottleneck and strategic battleground for the new energy industry's advancement.

1. Core Technology: Triple Safeguards Solve High-Voltage, High-Current Challenges
The reliable operation of high-voltage DC relays relies on the synergistic innovation of arc-quenching technology, contact materials, and sealing processes. Together, these three elements form the foundation for stable operation under high-voltage, high-current conditions.

a. Arc-Quenching Technology: The Core Method for Taming 3000°C Arcs.The arcs generated during the interruption of high-voltage DC circuits pose the primary safety threat, with their duration directly impacting contact lifespan and system safety. Current mainstream approaches offer two primary solutions. The most prevalent is magnetic arc-blow technology, which employs an internal magnetic coil to generate transverse Lorentz force, pulling the arc into a ceramic arc-blow grid for segmentation and cooling, achieving rapid extinction. The second is vacuum arc-extinguishing technology, leveraging the high insulation strength of a vacuum environment to block arc conduction, suitable for higher voltage levels. By suppressing arc generation through vacuum media within the contact gap and driving arc diffusion via magnetic fields, this method achieves zero gas emissions and exceptionally long service life, making it particularly suitable for high-frequency operation in extreme environments.

b.  Contact Materials: Precision Formulation Balancing Conductivity and Arc Resistance. Contacts serve as the "heart" of relays, requiring material selection that perfectly balances electrical conductivity, resistance to welding, and arc erosion tolerance.

c. Sealing Process: A Protective Barrier Against Environmental Interference. High-voltage applications demand exceptionally stringent sealing requirements, directly impacting the relay's insulation performance and lifespan. Therefore, we employ ceramic sealing technology. This technique achieves complete isolation between the contact chamber and the external environment, delivering an IP67 or higher protection rating. It withstands extreme temperatures ranging from -40°C to +85°C, as well as harsh conditions like humidity and dust. We also offer epoxy resin sealing technology. Vacuum potting fills contact gaps, combined with a hydrogen-mixed gas atmosphere, ensuring reliable 1000VDC voltage interruption within compact structures while reducing operational noise and adapting to confined vehicle installation spaces.

2. Safety and Reliability: From Passive Protection to Active Early Warning

The safety design of high-voltage DC relays encompasses the entire “prevention, monitoring, protection” process. Through zero arc flash implementation, anti-sticking mechanisms, and condition monitoring systems, a multi-layered safety protection system is established.

a. Zero Arc Flash Implementation: Blocking Arc Propagation Pathways. Zero arc flash is the core safety feature of high-voltage relays. The sealed arc-extinguishing chamber design confines arcs within ceramic or metal enclosures, preventing external splashes that could ignite surrounding combustibles.

b. Anti-Sticking Design: Dual Safeguards Against Fatal Failure. Contact sticking represents the most dangerous failure mode for high-voltage relays, potentially preventing circuit disconnection and triggering fires or electric shock incidents. The industry employs dual detection solutions to effectively prevent such failures.

c. Condition Monitoring: Lifecycle Safety Alerts. Modern high-voltage DC relays have evolved from simple actuators into intelligent sensing units. By integrating voltage and current sensors, they enable comprehensive condition monitoring to prevent sudden failures.

Technology-Empowered Solutions: Precisely Addressing High-End Application Pain Points

Facing the technical challenges of 800V high-voltage platforms and the safety demands of the new energy industry, our high-voltage DC relays offer multiple advantages. Additionally, our products integrate third-generation intelligent monitoring chips. With their technical characteristics of “ultimate safety, extended lifespan, and intelligent controllability,” our HVDC relays serve as the “safety guardian” for new energy vehicles and charging stations. They safeguard high-voltage platform upgrades, propelling the industry toward greater efficiency and enhanced safety and reliability.