Products
CAT-D48-ST273 Automotive Terminals  1
  • Sealable No
  • Primary Locking Feature On the Terminal
  • Automotive Terminal Wire Type Copper
  • Automotive Terminal Seal Type Family Seal or Unsealed
  • Crimp Type Indent
  • Typical Current Rating 7.5
  • Terminal & Splice Type Pin
  • Mating Pin Diameter 1.02
  • Automotive Terminal Interface Plating Gold (Au)
  • Automotive Terminal Termination Method Crimp
  • Wire Size 4
  • Wire Size .5
  • Wire Size Search .5
  • Wire Size Search 4
  • PCB Hole Diameter .89 – .99
  • Operating Temperature (Max) 80
  • Operating Temperature Range -55 – 125
  • Packaging Quantity 5000
  • Packaging Method Box
  • Terminal Transmits 0 – 24 A (Low Power)
  • Customer Preferred Contact Yes
CAT-AM7-FRB69 Other Hard Wired Boxes  1
  • Component Type Fuse Holder
  • Fuse Type Mini ATM Fuse
  • Compatible With Relay Type 280 Plug-In
  • Sealable Yes
  • Number of Fuses (Maximum) 6
  • Number of Relays (Maximum) 1
  • Number of Positions 27
  • Nominal Voltage Architecture 12
  • Secondary Locking No
  • Contact Current Rating (Max) 20
  • Centerline (Pitch) 7.8
  • Operating Temperature (Max) 125
  • Operating Temperature Range -40 – 125
  • IP Rating IP67
CAT-D487-CH8172 Automotive Housings  1
  • Connector & Housing Type Housing for Female Terminals
  • Connector System Bus Bar-to-Wire
  • Sealable Yes
  • Hybrid Connector No
  • Primary Locking Feature Integrated in Housing
  • Connector & Contact Terminates To Bus Bar
  • Number of Positions 2
  • Number of Rows 1
  • Blank Cavity Position 0
  • Operating Voltage 250
  • Operating Voltage 12
  • Nominal Voltage Architecture 12
  • Body Material PA GF
  • Cable Exit Angle 180
  • Primary Product Color Black
  • Connector Code 2
  • Mating Pin Diameter 1
  • Contact Current Rating (Max) 7.5
  • Mating Alignment Type Polarized
  • Strain Relief Add By Accessory
  • Connector Mounting Type Bulkhead
  • Mounting Feature Without
  • Terminal Position Assurance Yes
  • Centerline (Pitch) 4.19
  • Accepts Wire Insulation Diameter Range 1.35 – 3.05
  • Row-to-Row Spacing 4.45
  • Product Height 15.77
  • Product Length 28.4
  • Product Width 11.01
  • Operating Temperature (Max) 70
  • Operating Temperature Range -55 – 125
  • Circuit Application Power & Signal
  • UL Flammability Rating 12mm Flame Test per Standard UL-94
  • Degree of Protection IP68
  • Agency/Standard SAE J2030
  • Packaging Method Box
  • Packaging Quantity 60
  • Connector Position Assurance Capable No
  • Serviceable Yes
CAT-D799-CH8172 Automotive Housings  1
  • Connector & Housing Type Housing for Female Terminals
  • Connector System Wire-to-Wire
  • Sealable Yes
  • Hybrid Connector No
  • Primary Locking Feature Contact Retainer
  • Connector & Contact Terminates To Wire & Cable
  • Number of Positions 24
  • Number of Rows 4
  • Blank Cavity Position 0
  • Operating Voltage 250
  • Operating Voltage 250
  • Nominal Voltage Architecture 12
  • Body Material PA
  • Cable Exit Angle 180°
  • Primary Product Color Black
  • Connector Code 01
  • Mating Pin Diameter 1
  • Contact Current Rating (Max) 7.5
  • Mating Alignment Type Polarized
  • Strain Relief Add By Accessory
  • Connector Mounting Type Bulkhead
  • Mounting Feature Without
  • Terminal Position Assurance No
  • Centerline (Pitch) 4.4
  • Accepts Wire Insulation Diameter Range 1.02 – 2.41
  • Row-to-Row Spacing 4.42
  • Product Height 29.16
  • Product Length 27.94
  • Product Width 46.43
  • Operating Temperature (Max) 70
  • Operating Temperature Range -55 – 125
  • Circuit Application Power & Signal
  • UL Flammability Rating 20mm Flame Test per Standard UL-94
  • Degree of Protection IP68
  • Agency/Standard SAE J2030
  • Packaging Method Box
  • Packaging Quantity 21
  • Connector Position Assurance Capable No
  • Serviceable Yes
CAT-H396-CH8172 Automotive Housings  1
  • Connector & Housing Type Housing for Female Terminals
  • Connector System Wire-to-Wire
  • Sealable Yes
  • Hybrid Connector No
  • Primary Locking Feature Contact Retainer
  • Connector & Contact Terminates To Wire & Cable
  • Number of Positions 6
  • Blank Cavity Position 0
  • Operating Voltage 250
  • Operating Voltage 250
  • Nominal Voltage Architecture 12
  • Body Material PA GF
  • Cable Exit Angle 180°
  • Primary Product Color Black
  • Mating Pin Diameter 1.02
  • Contact Current Rating (Max) 7.5
  • Mating Alignment Type Polarized
  • Strain Relief Add By Accessory
  • Connector Mounting Type Bulkhead
  • Terminal Position Assurance No
  • Accepts Wire Insulation Diameter Range 1.02 – 2.1
  • Product Height 41.28
  • Product Length 38.3
  • Product Width 43.17
  • Operating Temperature (Max) 125
  • Operating Temperature Range -55 – 125
  • Circuit Application Power & Signal
  • UL Flammability Rating 20mm Flame Test per Standard UL-94
  • Degree of Protection IP67
  • Packaging Method Box
  • Packaging Quantity 1
  • Connector Position Assurance Capable No
  • Serviceable Yes
CAT-D487-W416 Automotive Connector Locks & Position Assurance  1
  • Connector & Contact Retention Accessory Type Secondary Lock
  • Connector System Wire-to-Board
  • Sealable No
  • Connector & Contact Terminates To Wire & Cable
  • Number of Positions 2
  • Primary Product Color Black
  • Primary Product Material PBT
  • Operating Temperature Range -55 – 125
  • Circuit Application Power & Signal
  • UL Flammability Rating UL 94HB
  • Packaging Method Box
  • Packaging Quantity 1
  • Serviceable Yes
CAT-D485-CH8172 Automotive Housings  1
  • Connector & Housing Type Housing for Female Terminals
  • Connector System Component-to-Wire
  • Sealable Yes
  • Hybrid Connector No
  • Primary Locking Feature Integrated in Housing
  • Connector & Contact Terminates To Wire & Cable
  • Number of Positions 2
  • Number of Rows 1
  • Blank Cavity Position 0
  • Operating Voltage 250
  • Operating Voltage 250
  • Nominal Voltage Architecture 12
  • Body Material PA GF
  • Cable Exit Angle 180°
  • Primary Product Color Black
  • Connector Code A
  • Mating Pin Diameter 1.02
  • Contact Current Rating (Max) 7.5
  • Mating Alignment Type Polarized
  • Strain Relief Add By Accessory
  • Connector Mounting Type Cable Mount (Free-Hanging)
  • Mounting Feature With
  • Terminal Position Assurance Yes
  • Centerline (Pitch) 4.19
  • Accepts Wire Insulation Diameter Range 1.35 – 3.05
  • Row-to-Row Spacing 7.11
  • Product Height 12.9
  • Product Length 27.56
  • Product Width 12.07
  • Operating Temperature (Max) 125
  • Operating Temperature Range -55 – 125
  • Circuit Application Power & Signal
  • UL Flammability Rating 20mm Flame Test per Standard UL-94
  • Degree of Protection IP68
  • Agency/Standard SAE J2030
  • Packaging Method Box
  • Packaging Quantity 200
  • Connector Position Assurance Capable No
  • Serviceable Yes
CAT-D487-H342 Automotive Headers  1
  • Connector System Wire-to-Board
  • Sealable Yes
  • Connector & Contact Terminates To Wire & Cable
  • Hybrid Header No
  • Number of Signal Positions 0
  • Number of Positions 2
  • PCB Mount Orientation Right Angle
  • Number of Rows 0
  • Number of Sections 1
  • Operating Voltage 250
  • Operating Voltage 250
  • Nominal Voltage Architecture 12
  • Voltage Rating (Max) 250
  • Voltage Rating (Max) 12
  • Primary Product Color Black
  • Connector Code A
  • Mating Pin Diameter 1.59
  • Contact Mating Area Plating Material Gold (Au)
  • Contact Current Rating (Max) 13
  • Termination Method to Printed Circuit Board Through Hole - Solder
  • PCB Mount Retention Type Mounting Screw
  • PCB Mount Retention With
  • Panel Mount Feature With
  • PCB Mount Alignment With
  • Connector Mounting Type Board Mount
  • Mounting Holes With
  • Locking Interface With
  • Centerline (Pitch) 1.45
  • Product Length 26.04
  • Product Width 23.52
  • PCB Thickness (Recommended) .78 – 2.36
  • Profile Height from PCB 27.43
  • Operating Temperature (Max) 125
  • Operating Temperature Range -55 – 125
  • Shielded No
  • Circuit Application Power
  • UL Flammability Rating Not tested
  • Degree of Protection IP68
  • Packaging Quantity 24
  • Packaging Type Box
  • Interface Number DT04-2P
CAT-D485-H342 Automotive Headers  1
  • Connector System Wire-to-Board
  • Sealable Yes
  • Connector & Contact Terminates To Wire & Cable
  • Hybrid Header No
  • Number of Signal Positions 12
  • Number of Positions 12
  • PCB Mount Orientation Right Angle
  • Number of Rows 2
  • Number of Sections 1
  • Operating Voltage 250
  • Operating Voltage 250
  • Nominal Voltage Architecture 12
  • Voltage Rating (Max) 250
  • Voltage Rating (Max) 250
  • Primary Product Color Black
  • Connector Code A
  • Mating Pin Diameter 1.02
  • Contact Mating Area Plating Material Gold (Au)
  • Contact Current Rating (Max) 7.5
  • Termination Method to Printed Circuit Board Through Hole - Solder
  • PCB Mount Retention Type Mounting Screw
  • PCB Mount Retention With
  • Panel Mount Feature With
  • PCB Mount Alignment Without
  • Connector Mounting Type Board Mount
  • Mounting Holes With
  • Locking Interface With
  • Centerline (Pitch) 4.19
  • Product Length 28.37
  • Product Width 33.02
  • PCB Thickness (Recommended) .78 – 1.57
  • Profile Height from PCB 35.54
  • Operating Temperature (Max) 125
  • Operating Temperature Range -55 – 125
  • Shielded No
  • Circuit Application Signal
  • UL Flammability Rating 20mm Flame Test per Standard UL-94
  • Degree of Protection IP67
  • Packaging Quantity 63
  • Packaging Type Box
  • Interface Number DTM04-12P
CAT-D485-W416 Automotive Connector Locks & Position Assurance  1
  • Connector & Contact Retention Accessory Type Secondary Lock
  • Connector System Wire-to-Wire
  • Sealable No
  • Connector & Contact Terminates To Wire & Cable
  • Number of Positions 2
  • Primary Product Color Black
  • Primary Product Material PBT
  • Operating Temperature Range -55 – 125
  • Circuit Application Power & Signal
  • UL Flammability Rating UL 94HB
  • Packaging Method Box
  • Packaging Quantity 15000
  • Serviceable Yes
Story
Nikola One, by Nikola Motor Company
Nikola One, by Nikola Motor Company
Bringing the high-tech world to the rugged world of long-haul trucking is a challenge we needed help with...we need suppliers willing to come fix problems or give expertise on-site.

Customer: Nikola Motor Company  

Focus: Transforming the transportation industry

Solution: Hydrogen-electric trucks engineered for zero-emission performance

Location: Phoenix, Arizona, USA

Websitehttps://www.nikolamotor.com 

LinkedInhttps://www.linkedin.com/company/nikola-motor-company

 

 

 

 

 

 

 

ENGINEERING CHALLENGES
• Affordable high-voltage connector solutions
• Charging and high-speed data solutions
• Speed of innovation, design and delivery

Nikola is seeking to transform the transportation industry by enabling a zero-emissions future. To achieve this daunting goal, they are building electric, hydrogen fuel cell Class 8 trucks, which they expect to bring to market in 2022. With the help of their technology partners, they successfully demonstrated at Nikola World in April 2019 how their fully functioning trucks will create a cleaner, efficient approach to the long-haul transport of goods.


Creating the technology required to power Nikola One and Nikola Two — their zero-emissions hydrogen fuel cell trucks — required the engineering team to solve for very unique requirements: to develop a powertrain capable of delivering up to 1,000 horsepower, with 2,000 ft-lbs of torque, and the capacity to carry a 110,000 pound load, achieve full recharge in 15 minutes, and display real-time performance data. To solve for high-voltage power connectivity, accelerated charging solutions, and high-speed data transmission, Nikola identified early on the need for a technology partner with proven high-voltage connectivity expertise, specifically around integrating the connectors, cables, sensors and other components that would optimize the performance, safety and reliability of their design.

“Bringing the high-tech world to the rugged world of long-haul trucking is a challenge we needed help with,” said Dane Davis, Nikola’s chief technology officer (CTO). “Long-term partnership is what we strive for. We need knowledgeable, consultative suppliers who are continually engaging with us, can innovate quickly and are flexible enough to meet our technology needs and strict timelines. When we have a problem, we need suppliers willing to come fix problems or give expertise on-site.”


Along with producing vehicles with true zero-emission impact on the environment, Nikola wanted to solve a major problem in the trucking industry. “Today, the number one problem in the trucking industry is availability of drivers for long-haul trucks — with a shortage of over 100K truckers in U.S.,” said Varoujan Sarkissian, Nikola’s head of electrical and control systems. “The technology in these vehicles will enable more capability to improve the experience of truckers.”


This technology includes video camera displays in rearview mirrors and digital displays equipped with programs to plan routes and track mileage, sleep, and expenses. By designing the trucks to help truckers, they are enabling transport companies to operate more efficiently. For example, the truck’s data architecture is designed to support more autonomous functionality, that can be used in the future when regulations allow. When the industry decides to use these features, transport companies can leverage the high-speed data connectivity to platoon vehicles and predict maintenance, repair, and overall cost-of-ownership, making it easier to manage the fleet and safer to operate on the road, while also helping reduce driver errors and fatigue issues.

  1. How Nikola's Hydrogen-Powered Electric Truck is Fueling a Revolution

Breaking barriers starts by asking a lot of questions. When Nikola started asking about high-voltage sensors, they turned to TE and our DEUTSCH line.

PARTNERSHIP SOLUTION
• High-voltage connectors and cable assemblies
• Deliver products, assistance, innovative solutions at speed
• Technical and design expertise

While developing the technology powering their hydrogen fuel-cell trucks, Nikola found that very few companies could provide what they needed, especially at the production speed required to meet their strict go-to-market timelines. With TE’s broad portfolio and breadth of expertise, Nikola identified early on that the company provided the opportunity to help them address their core engineering challenges.


Tony Heaton, Nikola’s head of battery systems, explains: “We have a full development cycle with fewer resources than most established OEMs, so we rely on TE and all our suppliers to provide products quickly while taking ownership of our milestones such as our most recent event, Nikola World. Our vehicles at Nikola World had a significant amount of TE products and they were able to expedite many of the products for us.”

The Nikola team.
The Nikola team, in the company's production facility.

In addition to getting products and prototypes quickly, Nikola was able to leverage expertise from across TE, partnering with engineers specializing in connectivity for automotive, commercial transportation, hybrid mobility and sensors. The Nikola and TE teams worked side-by-side to design and assemble the high-voltage connectors, cable assemblies and wire harnesses needed to run the trucks as well as develop solutions for optimizing the vehicle’s high-speed data connectivity and sensing capabilities.


Through this partnership, TE supplied prototypes and samples of high-voltage connectors—such as 30-amp and 60-amp connectors used for smaller battery cables, and HVP 1100 connectors for 300 amps and higher. Having TE part of the engineering team enabled Nikola to choose the optimal connectors and cable sizes needed to optimize performance in their battery system and hydrogen-fueled powertrain. For example, TE engineers helped Nikola select high-voltage connectors with integrated high-voltage interlocks (HVILs), which ensures that electrical current stops anytime the connectors are unmated. The HVILs are crucial for eliminating destructive arcing between terminals during unmating. The connectors are also fully shielded—with individual shields and insulation inserts—to prevent electromagnetic interference from or with other critical circuitry. For the battery charging system, high-voltage interlocking lines are built into the cable, so if a cable is cut, the current shuts down, making it safe for the driver, service technicians and first responders. HV cables and connectors can carry a maximum of 600 volts AC/1000 volts DC. The HVP cable assembly used will carry 200 amps from the battery to the motor and other devices. The high-voltage cables use silicone to provide dual insulation—around copper strands and over the braid shield and aluminum foil shield—to protect drivers and service personnel from accidental touching of the cable while current is flowing.


TE’s high-speed interconnection solutions were also needed to provide a reliable way to transfer high-volume data between various systems and displays. These play an important role in optimizing the driver’s experience and the efficiency of the operation. For example, the TE team helped Nikola engineer an IP6k9k USB Type C connector that optimizes the vehicle’s infotainment hardware, making this technology adaptable to use in all of Nikola’s different vehicles, not only in its trucks.


When building a high-voltage service disconnect for the battery, TE and Nikola collaborated with their tier-one supplier to develop prototype concepts, work through design implications, and iterate around engineering challenges and possible solutions. Joe Bolewitz, TE’s Industrial & Commercial Transportation chief technology officer, commented: “For the manual service disconnect, fusing technology isn’t quite where it needs to be yet in terms of reliability and robustness for Nikola’s trucks. We didn’t have the product, but we had enough knowledge to help them figure out what interface they’ll need and what everything will look like at higher voltage and current levels. This project is not just about supplying products, it’s about being a partner in helping them achieve their purpose.”

Inside view of Nikola Two.
Inside Nikola Two, the cab is equipped with advanced connectivity features.
Quote from Varoujan Sarkissian, Nikola’s head of electrical and control systems.
“The technology in these vehicles will enable more capability to improve the experience of truckers.”

TE’s Dinesh Shah, senior product engineer, explains how working with Nikola at their facility in Phoenix was crucial for success: “Nikola was under intense time pressures to get fully functioning vehicles built for Nikola World. We know how to build harnesses with our DEUTSCH connectors, crimping the contacts with our own hand tools and putting them in connector cavities. By working side-by-side with Nikola engineers we could give them the knowledge they were missing to help them finish builds faster and meet their time commitments. By collaborating this closely and understanding their needs more fully, we can also help them think of different ways to do things to accomplish their design goals.”

 

As Nikola finalizes their designs and prepares for mass production, TE is working to make the high-voltage connectors and cable assemblies more affordable to help Nikola trim costs. Assembly and manufacture for HV products is time consuming and very manual; workers need to strip the cable, fan out the braid, trim the braid, crimp the ferrule (done on crimping press with tools), apply components, and more. Mission alignment around making the transportation industry safer, more productive and sustainable has inspired the TE team to find ways to automate and improve the production process.

Nikola One, Nikola Two, and Nikola World are trademarks of Nikola Motor Company.

 
Related Materials
Nikola One, by Nikola Motor Company
Nikola One, by Nikola Motor Company
Bringing the high-tech world to the rugged world of long-haul trucking is a challenge we needed help with...we need suppliers willing to come fix problems or give expertise on-site.

Customer: Nikola Motor Company  

Focus: Transforming the transportation industry

Solution: Hydrogen-electric trucks engineered for zero-emission performance

Location: Phoenix, Arizona, USA

Websitehttps://www.nikolamotor.com 

LinkedInhttps://www.linkedin.com/company/nikola-motor-company

 

 

 

 

 

 

 

ENGINEERING CHALLENGES
• Affordable high-voltage connector solutions
• Charging and high-speed data solutions
• Speed of innovation, design and delivery

Nikola is seeking to transform the transportation industry by enabling a zero-emissions future. To achieve this daunting goal, they are building electric, hydrogen fuel cell Class 8 trucks, which they expect to bring to market in 2022. With the help of their technology partners, they successfully demonstrated at Nikola World in April 2019 how their fully functioning trucks will create a cleaner, efficient approach to the long-haul transport of goods.


Creating the technology required to power Nikola One and Nikola Two — their zero-emissions hydrogen fuel cell trucks — required the engineering team to solve for very unique requirements: to develop a powertrain capable of delivering up to 1,000 horsepower, with 2,000 ft-lbs of torque, and the capacity to carry a 110,000 pound load, achieve full recharge in 15 minutes, and display real-time performance data. To solve for high-voltage power connectivity, accelerated charging solutions, and high-speed data transmission, Nikola identified early on the need for a technology partner with proven high-voltage connectivity expertise, specifically around integrating the connectors, cables, sensors and other components that would optimize the performance, safety and reliability of their design.

“Bringing the high-tech world to the rugged world of long-haul trucking is a challenge we needed help with,” said Dane Davis, Nikola’s chief technology officer (CTO). “Long-term partnership is what we strive for. We need knowledgeable, consultative suppliers who are continually engaging with us, can innovate quickly and are flexible enough to meet our technology needs and strict timelines. When we have a problem, we need suppliers willing to come fix problems or give expertise on-site.”


Along with producing vehicles with true zero-emission impact on the environment, Nikola wanted to solve a major problem in the trucking industry. “Today, the number one problem in the trucking industry is availability of drivers for long-haul trucks — with a shortage of over 100K truckers in U.S.,” said Varoujan Sarkissian, Nikola’s head of electrical and control systems. “The technology in these vehicles will enable more capability to improve the experience of truckers.”


This technology includes video camera displays in rearview mirrors and digital displays equipped with programs to plan routes and track mileage, sleep, and expenses. By designing the trucks to help truckers, they are enabling transport companies to operate more efficiently. For example, the truck’s data architecture is designed to support more autonomous functionality, that can be used in the future when regulations allow. When the industry decides to use these features, transport companies can leverage the high-speed data connectivity to platoon vehicles and predict maintenance, repair, and overall cost-of-ownership, making it easier to manage the fleet and safer to operate on the road, while also helping reduce driver errors and fatigue issues.

  1. How Nikola's Hydrogen-Powered Electric Truck is Fueling a Revolution

Breaking barriers starts by asking a lot of questions. When Nikola started asking about high-voltage sensors, they turned to TE and our DEUTSCH line.

PARTNERSHIP SOLUTION
• High-voltage connectors and cable assemblies
• Deliver products, assistance, innovative solutions at speed
• Technical and design expertise

While developing the technology powering their hydrogen fuel-cell trucks, Nikola found that very few companies could provide what they needed, especially at the production speed required to meet their strict go-to-market timelines. With TE’s broad portfolio and breadth of expertise, Nikola identified early on that the company provided the opportunity to help them address their core engineering challenges.


Tony Heaton, Nikola’s head of battery systems, explains: “We have a full development cycle with fewer resources than most established OEMs, so we rely on TE and all our suppliers to provide products quickly while taking ownership of our milestones such as our most recent event, Nikola World. Our vehicles at Nikola World had a significant amount of TE products and they were able to expedite many of the products for us.”

The Nikola team.
The Nikola team, in the company's production facility.

In addition to getting products and prototypes quickly, Nikola was able to leverage expertise from across TE, partnering with engineers specializing in connectivity for automotive, commercial transportation, hybrid mobility and sensors. The Nikola and TE teams worked side-by-side to design and assemble the high-voltage connectors, cable assemblies and wire harnesses needed to run the trucks as well as develop solutions for optimizing the vehicle’s high-speed data connectivity and sensing capabilities.


Through this partnership, TE supplied prototypes and samples of high-voltage connectors—such as 30-amp and 60-amp connectors used for smaller battery cables, and HVP 1100 connectors for 300 amps and higher. Having TE part of the engineering team enabled Nikola to choose the optimal connectors and cable sizes needed to optimize performance in their battery system and hydrogen-fueled powertrain. For example, TE engineers helped Nikola select high-voltage connectors with integrated high-voltage interlocks (HVILs), which ensures that electrical current stops anytime the connectors are unmated. The HVILs are crucial for eliminating destructive arcing between terminals during unmating. The connectors are also fully shielded—with individual shields and insulation inserts—to prevent electromagnetic interference from or with other critical circuitry. For the battery charging system, high-voltage interlocking lines are built into the cable, so if a cable is cut, the current shuts down, making it safe for the driver, service technicians and first responders. HV cables and connectors can carry a maximum of 600 volts AC/1000 volts DC. The HVP cable assembly used will carry 200 amps from the battery to the motor and other devices. The high-voltage cables use silicone to provide dual insulation—around copper strands and over the braid shield and aluminum foil shield—to protect drivers and service personnel from accidental touching of the cable while current is flowing.


TE’s high-speed interconnection solutions were also needed to provide a reliable way to transfer high-volume data between various systems and displays. These play an important role in optimizing the driver’s experience and the efficiency of the operation. For example, the TE team helped Nikola engineer an IP6k9k USB Type C connector that optimizes the vehicle’s infotainment hardware, making this technology adaptable to use in all of Nikola’s different vehicles, not only in its trucks.


When building a high-voltage service disconnect for the battery, TE and Nikola collaborated with their tier-one supplier to develop prototype concepts, work through design implications, and iterate around engineering challenges and possible solutions. Joe Bolewitz, TE’s Industrial & Commercial Transportation chief technology officer, commented: “For the manual service disconnect, fusing technology isn’t quite where it needs to be yet in terms of reliability and robustness for Nikola’s trucks. We didn’t have the product, but we had enough knowledge to help them figure out what interface they’ll need and what everything will look like at higher voltage and current levels. This project is not just about supplying products, it’s about being a partner in helping them achieve their purpose.”

Inside view of Nikola Two.
Inside Nikola Two, the cab is equipped with advanced connectivity features.
Quote from Varoujan Sarkissian, Nikola’s head of electrical and control systems.
“The technology in these vehicles will enable more capability to improve the experience of truckers.”

TE’s Dinesh Shah, senior product engineer, explains how working with Nikola at their facility in Phoenix was crucial for success: “Nikola was under intense time pressures to get fully functioning vehicles built for Nikola World. We know how to build harnesses with our DEUTSCH connectors, crimping the contacts with our own hand tools and putting them in connector cavities. By working side-by-side with Nikola engineers we could give them the knowledge they were missing to help them finish builds faster and meet their time commitments. By collaborating this closely and understanding their needs more fully, we can also help them think of different ways to do things to accomplish their design goals.”

 

As Nikola finalizes their designs and prepares for mass production, TE is working to make the high-voltage connectors and cable assemblies more affordable to help Nikola trim costs. Assembly and manufacture for HV products is time consuming and very manual; workers need to strip the cable, fan out the braid, trim the braid, crimp the ferrule (done on crimping press with tools), apply components, and more. Mission alignment around making the transportation industry safer, more productive and sustainable has inspired the TE team to find ways to automate and improve the production process.

Nikola One, Nikola Two, and Nikola World are trademarks of Nikola Motor Company.

 
CAT-D48-ST273 Automotive Terminals  1
  • Sealable No
  • Primary Locking Feature On the Terminal
  • Automotive Terminal Wire Type Copper
  • Automotive Terminal Seal Type Family Seal or Unsealed
  • Crimp Type Indent
  • Typical Current Rating 7.5
  • Terminal & Splice Type Pin
  • Mating Pin Diameter 1.02
  • Automotive Terminal Interface Plating Gold (Au)
  • Automotive Terminal Termination Method Crimp
  • Wire Size 4
  • Wire Size .5
  • Wire Size Search .5
  • Wire Size Search 4
  • PCB Hole Diameter .89 – .99
  • Operating Temperature (Max) 80
  • Operating Temperature Range -55 – 125
  • Packaging Quantity 5000
  • Packaging Method Box
  • Terminal Transmits 0 – 24 A (Low Power)
  • Customer Preferred Contact Yes
CAT-AM7-FRB69 Other Hard Wired Boxes  1
  • Component Type Fuse Holder
  • Fuse Type Mini ATM Fuse
  • Compatible With Relay Type 280 Plug-In
  • Sealable Yes
  • Number of Fuses (Maximum) 6
  • Number of Relays (Maximum) 1
  • Number of Positions 27
  • Nominal Voltage Architecture 12
  • Secondary Locking No
  • Contact Current Rating (Max) 20
  • Centerline (Pitch) 7.8
  • Operating Temperature (Max) 125
  • Operating Temperature Range -40 – 125
  • IP Rating IP67
CAT-D487-CH8172 Automotive Housings  1
  • Connector & Housing Type Housing for Female Terminals
  • Connector System Bus Bar-to-Wire
  • Sealable Yes
  • Hybrid Connector No
  • Primary Locking Feature Integrated in Housing
  • Connector & Contact Terminates To Bus Bar
  • Number of Positions 2
  • Number of Rows 1
  • Blank Cavity Position 0
  • Operating Voltage 250
  • Operating Voltage 12
  • Nominal Voltage Architecture 12
  • Body Material PA GF
  • Cable Exit Angle 180
  • Primary Product Color Black
  • Connector Code 2
  • Mating Pin Diameter 1
  • Contact Current Rating (Max) 7.5
  • Mating Alignment Type Polarized
  • Strain Relief Add By Accessory
  • Connector Mounting Type Bulkhead
  • Mounting Feature Without
  • Terminal Position Assurance Yes
  • Centerline (Pitch) 4.19
  • Accepts Wire Insulation Diameter Range 1.35 – 3.05
  • Row-to-Row Spacing 4.45
  • Product Height 15.77
  • Product Length 28.4
  • Product Width 11.01
  • Operating Temperature (Max) 70
  • Operating Temperature Range -55 – 125
  • Circuit Application Power & Signal
  • UL Flammability Rating 12mm Flame Test per Standard UL-94
  • Degree of Protection IP68
  • Agency/Standard SAE J2030
  • Packaging Method Box
  • Packaging Quantity 60
  • Connector Position Assurance Capable No
  • Serviceable Yes
CAT-D799-CH8172 Automotive Housings  1
  • Connector & Housing Type Housing for Female Terminals
  • Connector System Wire-to-Wire
  • Sealable Yes
  • Hybrid Connector No
  • Primary Locking Feature Contact Retainer
  • Connector & Contact Terminates To Wire & Cable
  • Number of Positions 24
  • Number of Rows 4
  • Blank Cavity Position 0
  • Operating Voltage 250
  • Operating Voltage 250
  • Nominal Voltage Architecture 12
  • Body Material PA
  • Cable Exit Angle 180°
  • Primary Product Color Black
  • Connector Code 01
  • Mating Pin Diameter 1
  • Contact Current Rating (Max) 7.5
  • Mating Alignment Type Polarized
  • Strain Relief Add By Accessory
  • Connector Mounting Type Bulkhead
  • Mounting Feature Without
  • Terminal Position Assurance No
  • Centerline (Pitch) 4.4
  • Accepts Wire Insulation Diameter Range 1.02 – 2.41
  • Row-to-Row Spacing 4.42
  • Product Height 29.16
  • Product Length 27.94
  • Product Width 46.43
  • Operating Temperature (Max) 70
  • Operating Temperature Range -55 – 125
  • Circuit Application Power & Signal
  • UL Flammability Rating 20mm Flame Test per Standard UL-94
  • Degree of Protection IP68
  • Agency/Standard SAE J2030
  • Packaging Method Box
  • Packaging Quantity 21
  • Connector Position Assurance Capable No
  • Serviceable Yes
CAT-H396-CH8172 Automotive Housings  1
  • Connector & Housing Type Housing for Female Terminals
  • Connector System Wire-to-Wire
  • Sealable Yes
  • Hybrid Connector No
  • Primary Locking Feature Contact Retainer
  • Connector & Contact Terminates To Wire & Cable
  • Number of Positions 6
  • Blank Cavity Position 0
  • Operating Voltage 250
  • Operating Voltage 250
  • Nominal Voltage Architecture 12
  • Body Material PA GF
  • Cable Exit Angle 180°
  • Primary Product Color Black
  • Mating Pin Diameter 1.02
  • Contact Current Rating (Max) 7.5
  • Mating Alignment Type Polarized
  • Strain Relief Add By Accessory
  • Connector Mounting Type Bulkhead
  • Terminal Position Assurance No
  • Accepts Wire Insulation Diameter Range 1.02 – 2.1
  • Product Height 41.28
  • Product Length 38.3
  • Product Width 43.17
  • Operating Temperature (Max) 125
  • Operating Temperature Range -55 – 125
  • Circuit Application Power & Signal
  • UL Flammability Rating 20mm Flame Test per Standard UL-94
  • Degree of Protection IP67
  • Packaging Method Box
  • Packaging Quantity 1
  • Connector Position Assurance Capable No
  • Serviceable Yes
CAT-D487-W416 Automotive Connector Locks & Position Assurance  1
  • Connector & Contact Retention Accessory Type Secondary Lock
  • Connector System Wire-to-Board
  • Sealable No
  • Connector & Contact Terminates To Wire & Cable
  • Number of Positions 2
  • Primary Product Color Black
  • Primary Product Material PBT
  • Operating Temperature Range -55 – 125
  • Circuit Application Power & Signal
  • UL Flammability Rating UL 94HB
  • Packaging Method Box
  • Packaging Quantity 1
  • Serviceable Yes
CAT-D485-CH8172 Automotive Housings  1
  • Connector & Housing Type Housing for Female Terminals
  • Connector System Component-to-Wire
  • Sealable Yes
  • Hybrid Connector No
  • Primary Locking Feature Integrated in Housing
  • Connector & Contact Terminates To Wire & Cable
  • Number of Positions 2
  • Number of Rows 1
  • Blank Cavity Position 0
  • Operating Voltage 250
  • Operating Voltage 250
  • Nominal Voltage Architecture 12
  • Body Material PA GF
  • Cable Exit Angle 180°
  • Primary Product Color Black
  • Connector Code A
  • Mating Pin Diameter 1.02
  • Contact Current Rating (Max) 7.5
  • Mating Alignment Type Polarized
  • Strain Relief Add By Accessory
  • Connector Mounting Type Cable Mount (Free-Hanging)
  • Mounting Feature With
  • Terminal Position Assurance Yes
  • Centerline (Pitch) 4.19
  • Accepts Wire Insulation Diameter Range 1.35 – 3.05
  • Row-to-Row Spacing 7.11
  • Product Height 12.9
  • Product Length 27.56
  • Product Width 12.07
  • Operating Temperature (Max) 125
  • Operating Temperature Range -55 – 125
  • Circuit Application Power & Signal
  • UL Flammability Rating 20mm Flame Test per Standard UL-94
  • Degree of Protection IP68
  • Agency/Standard SAE J2030
  • Packaging Method Box
  • Packaging Quantity 200
  • Connector Position Assurance Capable No
  • Serviceable Yes
CAT-D487-H342 Automotive Headers  1
  • Connector System Wire-to-Board
  • Sealable Yes
  • Connector & Contact Terminates To Wire & Cable
  • Hybrid Header No
  • Number of Signal Positions 0
  • Number of Positions 2
  • PCB Mount Orientation Right Angle
  • Number of Rows 0
  • Number of Sections 1
  • Operating Voltage 250
  • Operating Voltage 250
  • Nominal Voltage Architecture 12
  • Voltage Rating (Max) 250
  • Voltage Rating (Max) 12
  • Primary Product Color Black
  • Connector Code A
  • Mating Pin Diameter 1.59
  • Contact Mating Area Plating Material Gold (Au)
  • Contact Current Rating (Max) 13
  • Termination Method to Printed Circuit Board Through Hole - Solder
  • PCB Mount Retention Type Mounting Screw
  • PCB Mount Retention With
  • Panel Mount Feature With
  • PCB Mount Alignment With
  • Connector Mounting Type Board Mount
  • Mounting Holes With
  • Locking Interface With
  • Centerline (Pitch) 1.45
  • Product Length 26.04
  • Product Width 23.52
  • PCB Thickness (Recommended) .78 – 2.36
  • Profile Height from PCB 27.43
  • Operating Temperature (Max) 125
  • Operating Temperature Range -55 – 125
  • Shielded No
  • Circuit Application Power
  • UL Flammability Rating Not tested
  • Degree of Protection IP68
  • Packaging Quantity 24
  • Packaging Type Box
  • Interface Number DT04-2P
CAT-D485-H342 Automotive Headers  1
  • Connector System Wire-to-Board
  • Sealable Yes
  • Connector & Contact Terminates To Wire & Cable
  • Hybrid Header No
  • Number of Signal Positions 12
  • Number of Positions 12
  • PCB Mount Orientation Right Angle
  • Number of Rows 2
  • Number of Sections 1
  • Operating Voltage 250
  • Operating Voltage 250
  • Nominal Voltage Architecture 12
  • Voltage Rating (Max) 250
  • Voltage Rating (Max) 250
  • Primary Product Color Black
  • Connector Code A
  • Mating Pin Diameter 1.02
  • Contact Mating Area Plating Material Gold (Au)
  • Contact Current Rating (Max) 7.5
  • Termination Method to Printed Circuit Board Through Hole - Solder
  • PCB Mount Retention Type Mounting Screw
  • PCB Mount Retention With
  • Panel Mount Feature With
  • PCB Mount Alignment Without
  • Connector Mounting Type Board Mount
  • Mounting Holes With
  • Locking Interface With
  • Centerline (Pitch) 4.19
  • Product Length 28.37
  • Product Width 33.02
  • PCB Thickness (Recommended) .78 – 1.57
  • Profile Height from PCB 35.54
  • Operating Temperature (Max) 125
  • Operating Temperature Range -55 – 125
  • Shielded No
  • Circuit Application Signal
  • UL Flammability Rating 20mm Flame Test per Standard UL-94
  • Degree of Protection IP67
  • Packaging Quantity 63
  • Packaging Type Box
  • Interface Number DTM04-12P
CAT-D485-W416 Automotive Connector Locks & Position Assurance  1
  • Connector & Contact Retention Accessory Type Secondary Lock
  • Connector System Wire-to-Wire
  • Sealable No
  • Connector & Contact Terminates To Wire & Cable
  • Number of Positions 2
  • Primary Product Color Black
  • Primary Product Material PBT
  • Operating Temperature Range -55 – 125
  • Circuit Application Power & Signal
  • UL Flammability Rating UL 94HB
  • Packaging Method Box
  • Packaging Quantity 15000
  • Serviceable Yes