Smarter Connector Design for Electrification: Innovations Driving Performance, Safety & Sustainability

What You’ll Learn:

How lithium-ion battery adoption is reshaping connector requirements
The impact of tool-less cartridge systems on serviceability and labor efficiency
Why strain relief and thermal management are critical for connector reliability
The role of smart connectors in next-gen electrified systems

In machine design, connectors are essential components that facilitate electrical connections. As electrification expands across industries, connector design is undergoing significant transformation to meet rising demands for mechanical strength, environmental durability and electrical performance. Joe Ferris, market segment manager at Anderson Power, a maker of high-powered battery connectors, spoke with Machine Design about how connector innovation is enabling smarter electrification and addressing emerging challenges.

Anderson Power’s roots trace back to the 1800s, marching alongside early electrical innovations like trolley pole systems for urban trains. Today, their legacy lives on in robust, high-current battery connectors used worldwide. Ferris, bringing years of customer facing electrification experience, leads market-driven product development that aligns with evolving customer needs and technology trends.

Electrification’s rapid growth is not limited to traditional sectors but increasingly embraces new markets that have been historically reliant on fossil fuels. This shift, together with the widespread adoption of lithium-ion batteries, compels connectors to handle higher power loads and smarter battery communication, Ferris said. Unlike older lead-acid systems, lithium batteries charge faster, tolerate more flexible charging cycles and produce more heat—all factors that Ferris points out necessitate new connector strategies.

Simplifying Assembly with Tool-less Cartridge Systems

In response to labor challenges and the need for swift serviceability, Anderson Power’s tool-less cartridge design modularizes connector assembly. Ferris says that by moving complex wiring and contacts outside the confined connector housing, the system reduces assembly time, minimizes specialized tooling and facilitates rapid field repairs. And this design has proven impactful; some material handling customers reduce their repair team head count by two-thirds while boosting equipment uptime and revenue, Ferris said.

Strain Relief for Performance, Safety

Vibration and movement pose significant reliability risks at the contact level, often the weakest link in the power transfer chain. Effective strain relief that anchors the wire to the connector body mitigates these risks. “The immediate thing is taking strain off the wire, but strain relief also protects contacts from vibration and displacement. If contacts move even slightly,” Ferris said, “you reduce power transfer efficiency and generate heat, causing premature failures.”

By maintaining contact integrity, connectors operate safely and reliably, mitigating costly downtime. “Heat buildup leads to safety concerns and downtime. By keeping the contacts cool and stable you maintain reliable and safe operation,” he said.

Ferris adds that it also is important to address harsh environments and thermal management. Meeting global standards such as CSA, UL and TUV is fundamental. These certifications mandate rigorous testing for temperature resistance, moisture ingress and corrosion, ensuring connectors perform safely under environmental extremes.

“We design connectors to meet standards, but ultimately the equipment manufacturer must ensure the entire system, including wiring and usage, is within safe operating limits. Otherwise, heat buildup and failures become real risks.”

Today’s trends toward higher power and faster charging generate more heat. Advanced approaches like temperature sensing embedded within connectors and even liquid-cooled cables for large battery systems illustrate how thermal management is becoming a critical design focus. “You might throttle back your power. To stay within safety margins, giving room for unexpected operating conditions, which improves longevity and safety.”

Connecting to the Future

Ferris says that future trends will include smart connectors and data integration. Beyond power delivery, connectors are evolving to carry data reflecting battery health and temperature, feeding into smarter systems and controllers. This capacity unlocks diagnostic and safety features that are essential for next-generation electrified machinery. “Lithium batteries are smarter,” Ferris said. “They can charge whenever you want and absorb power faster, but that creates more heat. Liquid cooled connectors for high voltage are emerging. For less complex systems, temperature sensors integrated into connectors provide vital monitoring.”

The growing use of sealed connectors and charging environments also opens new use cases, Ferris added, such as outdoor or rugged location charging previously limited by safety concerns. “Connectors need to deliver data from batteries to controllers, enabling performance optimization and safety.”

When it comes to collaboration and best practices for engineers, Ferris stresses interdisciplinary collaboration. Electrical, mechanical and software engineers must harmonize early in the design cycle to meet demanding specifications. “It starts with requirements laid out fully,” he said. “Simple mechanical solutions can yield elegant designs like the cartridge system easing serviceability, but all disciplines must align to hit performance, safety and cost targets.”

Knowing environmental conditions, aligning cost considerations and respecting system-wide performance thresholds are necessary for successful connector selection. Also, adherence to standards like DIN fosters safety, interoperability and development efficiency.

Connector placement in the equipment is deceptively important, too, Ferris noted. “Don’t overlook the simple stuff,” he said. “Connector placement is critical. Put the connector in the wrong place, and it can cause premature failures and trouble down the line,” he said. Designers must consider protection from external stresses to maximize the connectors lifespan in operational use.

Beyond technical innovation, Ferris noted that Anderson Power aligns with the Responsible Business Alliance for social, environmental and ethical commitments across their supply chain. This holistic approach ensures sustainability efforts extend beyond materials and processes to the broader ecosystem.