The energy sector is rapidly evolving with the integration of smart grids, distributed energy resources (DERs), and smart monitoring systems, reshaping how energy is generated, distributed, and consumed. Molex supports this transformation with innovative high-power connector solutions and busbars like PowerWize, SW1, and PowerPlane, ensuring safe and efficient current movement to drive a sustainable energy future.
Emerging Trends in Energy Storage, Distribution and Consumption
Recently, major investments have risen across electrification infrastructure, grid modernization and rural connectivity. The reason? The rapid emergence of a widespread energy revolution, including the introduction of smart grids, the unification of distributed energy resources (DERs) and the significance of smart monitoring.
Advancements in Smart Grid Technology
The first major shift associated with this trend is increasing requirements for energy generation efficiency using smart grids. As manufacturers transform aging infrastructures into modern electrified networks, they can seamlessly navigate the benefits of conventional, renewable and stored energy sources. Smart grids consist of a variety of sensors to closely monitor usage and identify system faults before they become more significant problems, enabling allocation of energy where and when it’s needed most and from what source. Plus, the increasing capabilities of artificial intelligence (AI) and machine learning (ML) enable smart grids to react more quickly to usage trends, outages or other failures. This responsiveness provides numerous advantages. For example, with renewables like solar and wind that have cyclical downtimes, battery energy storage systems (BESS) are incorporated into the broader grid and used to capture excess energy for later use.
Islanding and Energy Distribution
The future of grid modernization is with a distributed approach through DERs. These small-scale energy generators, often located near the point of consumption, may involve traditional fuel sources such as diesel generators, renewables such as solar panels or battery storage. Typically segmented into numerous microgrids of self-powered islands, separate DERs combine to offset — or even outproduce — the output volume of traditional sources. Also, with microgrids being miniaturized into nanogrids that power a single structure such as a data center, connectivity becomes critical to the safe and successful operation of a microgrid. Islanding and then re-integrating portions of the grid introduce risk of equipment damage and injury, such as those caused when a worker is unaware if equipment is disconnected.
Home energy management systems, microgrids covering small communities, hospitals and industrial parks are all examples of DERs. Electric vehicle (EV) charging incorporates DERs by leveraging solar panels on charging stations to reduce the need to pull from the grid itself. In the case of a power outage, the DERs within the microgrid will take over production, keeping power flowing for whatever is connected to the microgrid. Overall, DERs help to reduce strain on the grid and avoid the high costs of distribution infrastructure over long distances.
Monitoring the Point of Consumption
Much like sources of generation, energy utilization is also undergoing significant transformation through smart meters. An extension of the smart grid, smart meters enable two-way communication between the consumer and supplier. The meters show households, businesses and governments a high-resolution picture of their minute-to-minute usage, supporting energy awareness. Smart metering utilized in data centers can deliver significant benefit by counteracting even the smallest of power outages causing data loss or disruption. Through close monitoring of electrical output, wasteful activities can be eliminated and replaced by more efficient operations.
High-Power Connectors for Compact Spaces
In response to ever-evolving energy systems, Molex offers a comprehensive portfolio of high-power connector solutions and busbars that ensure high currents move safely through assemblies without sacrificing performance or reliability.
PowerWize Connectors
Since power efficiency is critical to cost management in large power-consuming operations such as data centers, Molex PowerWize High-Voltage, High-Current Wire-to-Board/Wire-to-Busbar Connectors are designed with COEUR socket technology in their crimp contacts. This innovative technology enables PowerWize connectors to offer low contact resistance and low voltage drop at the contact interface due to its multiple contact beams. Additionally, as energy systems evolve, it is critical that energized equipment is safe to handle if a new device is being installed or a defective device is being removed and replaced. PowerWize headers and receptacles are designed to comply with industry-standard touch-safe requirements, providing ample protection across numerous industries. PowerWize Connectors offer even more versatility with two different sizes, 6.00 and 8.00mm, suitable for applications requiring up to 1,000V and 190.0A. Additionally, PowerWize crimp sockets can accept 1/0, 2, 4, 6, 8 or 10 AWG wires.
SW1 Connectors
Dense electronic packaging demands a low mated height between a cable assembly and its printed circuit board or busbar. With a compact design, Molex SW1 Wire-to-Board/Wire-to-Busbar Interconnects provide ample solutions to space limitations. The COEUR socket, with its multiple contact beams, creates a large contact surface at the mating interface and enables mated interconnects that are lower in height. SW1 Connectors are also manufactured with a shorter length and narrower width than comparable solutions using hyperbolic sockets, measuring about 1/3rd lower in height and 1/3rd shorter than similar products on the market. Design flexibility is another significant aspect of the SW1 family. Its z-axis mating configuration eliminates cable bend radius complications, making it an ideal solution for applications where space is limited. For engineers and designers aspiring to improve energy efficiency despite space restrictions in systems such as DERs and microgrids, SW1 is an effective option.
PowerPlane Busbar Connectors:
In addition to space constraints, designers are often faced with system alignment challenges. To overcome obstacles in accurate alignment when mating connectors, PowerPlane Busbar Power Connectors deliver +/- 1.00mm alignment to help ensure correct mating and help prevent potential damage. These connectors also enable engineers to meet design demands within multiple industries with high-current performance along with various configurations and feature options. PowerPlane connectors offer high reliability for enhanced performance and are excellent for a wide range of power distribution applications, such as DERs, nanogrids and smart grids. Manufacturers often explore supply continuity and additional suppliers for their design options — PowerPlane Busbar Power Connectors meet the needs of a second source by providing direct board and footprint drop-in replacements for competitors’ products.
A Guiding Light in an Exciting Future
The future is ripe for the rapid development of smart grids, DERs and smart monitoring. As EV charging infrastructure expands, more fail-safe mechanisms are incorporated into critical systems and homes become more energy independent, electrification and energy management applications will continue to delve into dynamic and potentially uncharted terrain. With an 80-year legacy of innovation in interconnect solutions, global manufacturing capabilities and a distribution footprint that includes valued partners, such as Arrow, Molex is well poised to help usher in the energy solutions of tomorrow.
1. SW1 Connectors
2. Terminal Blocks
3. Mini-Fit Connectors
4. Off-the-Shelf Power and Signal Discrete Wire Cable Assemblies
5. Nano-Fit Connectors
6. Busbars
7. PowerPlane Busbar Connectors
8. Mega-Fit Connectors
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