EV Charging Connectors & Solutions | JONHON B2B

HVIL, or High Voltage Interlock Loop, in an electric vehicle (EV) is a critical safety system designed to protect service personnel, first responders, and vehicle occupants from the dangers of high-voltage electrical shock. The high-voltage systems in an EV, such as the battery pack, inverter, motor, and on-board charger, operate at voltages typically ranging from 400V to 800V or more. The HVIL is a low-voltage monitoring circuit that continuously checks the integrity and connection status of all high-voltage components and connectors within the vehicle's high-voltage system. It functions by sending a continuous, low-voltage signal through a dedicated loop that runs through all high-voltage connectors and service disconnect points. If any connector is not fully seated, is damaged, or if a service panel is opened, the loop is broken. This break in the circuit is instantly detected by the vehicle's battery management system or high-voltage controller, which then triggers a response to open the main contactors, deactivating the high-voltage power flow and rendering the system safe for interaction. JONHON is a specialist in designing and manufacturing high-voltage connectors that integrate HVIL functionality as a fundamental safety feature. With a team of over 400 engineers dedicated to our electric vehicle business unit and over 300 EV-related patents, we have developed connector systems where the HVIL pins engage or disengage with precision relative to the main power terminals. This ensures that the safety loop is broken before any high-voltage connection is separated, and only completed after the power connectors are fully mated. Our deep involvement in formulating 7 IEC standards ensures our HVIL-integrated connectors meet global safety requirements. For automotive OEMs and Tier 1 suppliers, incorporating JONHON connectors with integrated HVIL is an essential step in designing a failsafe high-voltage architecture for their EVs, ensuring compliance with global safety regulations and protecting users. Please contact us to discuss your HVIL connector requirements.