Electric vehicle industry fuels trend for high-voltage automotive relays

R&D in the automotive relay sector is directed toward meeting the demand for greener, cleaner cars, buses and other vehicles.

As the shift to electric vehicles or EVs continues, driven by a rise in awareness of the need for environmental protection, a change is happening in the automotive relay sector. Conventional types have taken a back seat as attention turns to development of the high-voltage variants used in electric cars, two-, three- and four-wheelers, buses and trucks. Such components have a rated voltage of 370VDC or even 576VDC, high load and shock resistance, and enhanced rupture capability, in addition to being lightweight.

In China, where there are national and local subsidies for buying EVs, this trend promises a growth rate as high as 41 percent for the high-voltage relay market in 2020. The estimated value is $597 million over that of 2019, according to Zhiyan Consulting. In contrast, the mainstream low-voltage category is expected to post an increase of something over 7 percent. In export markets, automotive relays, which posted an overall annual increase of about 10 percent in recent years, will remain at this rate for the next two years.

China's electromechanical component suppliers are working to release more such models. Neptune Electric, a major player in this line, started developing high-voltage relays for EVs in 2011 and has already applied for more than 50 patents. The company is soon to install four production lines with total annual capacity exceeding 3 million units. Zhejiang Innuovo offers models with 450VDC or 750VDC rated load voltage.

Besides relays for EVs, manufacturers are improving the performance of low-voltage relays for conventional motor vehicles, making them safer and more reliable. They are also developing designs that are lighter.

Low-voltage types can control high power loads, are vibration- and shock-resistant and operate in a wider temperature range. Compared with other kinds of relays with -40 to 85 C operating temperature, those designed for automotive applications operate at -40 to 125 C, and have dust, sand, water and corrosion resistance.

Most suppliers ensure automotive relays meet CCC, CE, CSA, RoHS, TÜV and UL requirements.

Production in 1H20 was affected by the COVID-19 pandemic, not only halting expansion plans but also resulting in a significant drop in output. However, suppliers say the situation improved in the following quarter, buoying their hopes. Many have signaled readiness to receive more orders from domestic and overseas clients. Ningbo Yod Electronic Technology Co. Ltd is looking to raise its yield by 10 percent or more in 2021 in anticipation of gradual demand recovery.

Hundreds of manufacturers comprise the automotive relay sector in China. More than two-thirds are small and midsize homegrown companies. Xiamen Hongfa, Shanghai Hugong and Guizhou Space Appliance are some of the larger players.

The majority of these suppliers also cater to other applications, and make components such as transformers and power supplies. Relays for vehicles make up between 20 and 70 percent of total shipments.

To compete with foreign businesses with factories in China, domestically owned companies highlight better price-performance ratio.

Over half of automotive relays shipped out of China come from global industry giants such as Tyco, Panasonic, LS and Omron.

The main production bases in China are in the coastal and central provinces of Guangdong, Zhejiang, Sichuan and Shaanxi. The key city locations are Shenzhen, Dongguan, Zhongshan, Ningbo, Chengdu and Xi'an. These areas will continue to attract local and foreign entrants to the relay market.

Relays for typical green vehicles

Widely produced low-voltage automotive relays for motor vehicles have 12 or 24VDC rated voltage, 1.6 to 2W rated power, 500VAC withstand voltage and 100Mohm insulation resistance.

For EVs, common high-voltage models come in versions with a rated voltage ranging from 12 to 1,000VDC, withstand voltage of up to 4,000V and insulation resistance of 1,000Mohm.

Both types have -40 to 85 C operating temperature, which suits applications such as vehicle lights and windows.

Automotive relays that operate -40 to 125 C are also available. These include the SFT-Auto relay_821 model from Shaanxi Fortune Industries Co. Ltd and the 012-1H model from Liuzhou ShuangFei Auto Electric Appliances Mfg Co. Ltd.

Units with an IP65 or IP67 rating are available.

Most companies use domestically sourced components and materials such as coils, magnetic cores, armatures, springs and contact bases, turning to foreign providers only when customers specify them.

The costs of manufacturing inputs are expected to remain generally stable and keep the prices of automotive relays unchanged. Some suppliers may lower product quotes to attract more orders.

The products in this gallery have been handpicked by our China-based market analyst for representing current trends in automotive relays from China makers.

Automotive relay with 6VDC, 1A rated load

The automotive relay offered by Liuzhou Shuangfei Auto Electric Appliances Mfg Co. Ltd, the 012-1H model, has 14V contact load voltage, 6VDC, 1A rated load and 100Mohm insulation resistance at 500VDC. Response time is 10ms. The 34g unit operates in -40 to 125 C.

An order of at least 200 units has a delivery lead-time of 7 days.

Inquire now

Automotive relay with 4.8, 24W coil power consumption

From Ningbo Yod Electronic Technology Co. Ltd, the model 86T-12V-120A automotive relay, with 1H contact form, has 120(220A) maximum contact load capacity, 120, 140 or 200A maximum switching current. The rated coil voltage is 6, 12, 24 or 48V and the coil power consumption is 4.8W for intermittent use or 24W for continuous use.

The minimum order for this 46x46x44.5mm relay is 200 units. Delivery is within 15 days.

Inquire now

Automotive relay with 12 to 24VDC rated voltage

Model SFT-Auto Relay_821 from Shaanxi Fortune Industries Co. Ltd has 27VDC maximum operating and 12 to 24VDC rated voltages, 100ohm insulation resistance, and 10ms operating and release time. Its operating temperature is -40 to 125 C.

The 500-unit minimum order is for delivery within 10 days.

Inquire now

Automotive relay supports 560W switching

This automotive relay from Shenzhen Rocfly Blue Electronic Co. Ltd, the LCR01 model, has 14VDC, 40A rated load, 100mohm contact resistance at 1A, 24VDC and 10ms response time. Its maximum switching voltage, current and power are 30VDC, 40A and 560W. The unit operates in -55 to 85 C. It comes in 55g water-resistant and 35g nonwater-resistant versions.

The minimum order is 500 units. Delivery is within 7 days.

Inquire now