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1. What are DC relays and microswitches suitable for electric mobility?
With the advent of electric mobility, there are high expectations for the realization of a decarbonized society and new means of transportation to support an aging society. On the other hand, design issues related to practicality are also increasing. The mobility industry requires designs that take into account greater safety, energy efficiency, design, and functionality.
DC relays and microswitches suitable for electric mobility are components that can stably energize and interrupt DC loads even under vibration and shock. Furthermore, the low power consumption and small size of these components will make them more valuable for mobility. Therefore, it is important to select these components from the three perspectives: "stable energizing and interruption", "low power consumption", and "miniaturization”.
*1 If you are considering using them for automotive applications, please refer to the Automotive Relays and Automotive Switches web pages.
2. Are you having trouble with these things?
- Selection points for components to address engineers' concerns
In electric mobility, design issues include stable energization and interruption of DC loads to have stable electric control, realization of low power consumption drive for high energy efficiency, and miniaturization and weight reduction of mechanisms to achieve both design and functionality.
The following three points need to be considered for selecting DC relays and microswitches to solve each problem.
- (1) Ability to energize and interrupt DC loads stably even under vibration and shock conditions
- (2) Eliminating wasteful power consumption
- (3) Thoroughly small in size
Examples of problems faced by engineers
We want to realize safety control of DC loads in various driving environments.
"Larger battery capacity. Is that DC load control really safe?"
Selection point (value provided by OMRON)
Stable energizing and interruption even under vibration and shock
Examples of problems faced by engineers
We want to realize low power consumption design while maintaining/improving functionality
"People talk about energy savings, but we have to add the ability to interrupt large loads..."
Selection point (value provided by OMRON)
Waste-free power consumption
Examples of problems faced by engineers
We want to achieve both functionality and design
"We want functionality, but we also want a slim, compact design..."
Selection point (value provided by OMRON)
Thoroughly pursued ultra-compact
3. DC relays and microswitches for electric mobility recommended by OMRON
Introduced separately for DC relays (high capacity), DC relays (low capacity), and microswitches are: OMRON's recommended products that meet the needs of "stable energizing and interruption", "low power consumption", and "miniaturization".
3-1. DC relays (high capacity range)
Electric mobility has three major components: charging device, battery (DC power source), and DC load. DC relays are required to play two roles, one for interrupting and the other for pre-charging. This is an application where safety is strongly required.
*2 To learn more about our recommendations in chargers, please visit Solutions for Energy Market.
For emergency interruption and pre-charge applications
-- Choose the G9E□ series
[Stable energizing and interruption] To safely energize and interrupt DC loads even under vibration and shock conditions
G9EK-1
Rated load: 500 VDC/120 A
G9EK-1-E
Rated load: 500 VDC/200 A
G9EK-1-EX
Rated load: 500 VDC/250 A
Materializing shocking "shockproof performance"
No malfunction even in shocks up to 100 G*3 that occur in short shutdowns.
Shock resistance performance when energized G9EK-1 [G]
Note: Dimensions are in mm (typical value)
*3 The impact of a 350 km/h car coming to a stop in 0.1s is about 100 G.
[Miniaturization] For a small size and high inrush resistance for pre-charge applications
G9EJ
Rated load: 400 VDC/15 A
G9EJH
Electrical endurance (condenser load): 800 VDC/30 A
"High inrush resistance + long life" that can be achieved even with a small size
Combines high inrush resistance and electrical durability despite its small size.
(Guaranteed 100,000 times at 400 VDC/25 A)
Example of Reference Data G9EJ-1
(1) Operating voltage fluctuation rate x Number of electrical endurance cycles*6
(2) Voltage drop value x Number of electrical endurance cycles*7
Note: Dimensions are in mm (typical value)
*6 Measured at 400 V/25 A, 100,000 test cycles, normal temperature and humidity, 3300 µF capacitor load, n = 3
*7 Measured with voltage value at 15 A energization, n = 3
Note: The values are actual values and are not guaranteed.
[Low power consumption] To achieve both high-capacity interruption/control and power saving
G9EK-1
Rated load: 500 VDC/120 A
G9EK-1-E
Rated load: 500 VDC/200 A
G9EK-1-EX
Rated load: 500 VDC/250 A
Low power consumption despite high short-circuit performance
It has a high short-circuit performance of 5000 A, yet consumes only 4 W.
Example of Reference Data G9EK-1-U
Note: Dimensions are in mm (typical value)
*4 Comparison of short-circuit performance between G9EA (approx. 2000 A) and G9EK-1-U (approx. 5000 A)
*5 Comparison of power consumption between G9EA (approx. 5 W) and G9EK-1-U (approx. 4 W)
(Informative) OMRON's main lineup of high capacity DC relays (by rated load)
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Note:
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The above is for a resistive load.
Refer to the datasheet on the detail page for more information.
Note: If you are considering using them for automotive applications, please refer to the Automotive Relays web page.
3-2. DC relays (low capacity range)
DC relays are also used for applications in the low capacity range (e.g., control of motors, fans, and heaters). Since these applications require strict design in a limited space, relays are characterized by their high switching capacity and thorough miniaturization requirement at the same time (minimization of the volume and area).
Example of motor control circuit
Example of fan control circuit
For motors, fans, heaters, and other applications
-- G8□ series
[Miniaturization] To achieve both minimum mechanism and high electric load control
G8K
Rated load: 14VDC/5A
Outstanding! Industry's smallest class*8 ultra-compact DC relay
・Unique structural design realizes ultra-compact size (specialized for short-time energization).
・The terminal arrangement simplifies PCB wiring and enables ultra-high-density mounting in positive and negative circuits.
Note: Dimensions are in mm (typical value)
*8 According to OMRON's research in October 2023
[Miniaturization] To achieve a high heat dissipation design with less than conventional PCB size
G8G
Rated load: 14 VDC/35 A
28 VDC/14 A
Compact DC relay with "small footprint"
Reduced relay footprint enables high heat dissipation design
Note: Dimensions are in mm (typical value)
(Rated voltage: For 12 VDC model)
[Stable energization and miniaturization] To achieve both stable energization in various environments and minimization of the mechanism
G8PM
Rated load: 14 VDC/45 A
Unique twin contact structure for high current-carrying reliability
- "Capacity of 40 to 60 A, yet this small"
・Improved contact reliability with a structure that stabilizes contact resistance.
・Compact design with high heat dissipation characteristics.
・Latching model available. Contributes to power saving applications.
Large heat radiation area allows dispersion of heat load
Note: Dimensions are in mm (typical value)
(Informative) OMRON's main lineup of low capacity DC compact relays
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Note:
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The above is for a resistive load.
Refer to the datasheet on the detail page for more information.
Note: If you are considering using them for automotive applications, please refer to the Automotive Relays web page.
3-3. Microswitches
Electric mobility requires a variety of detection mechanisms to support the application in order to enhance functionality. Examples include charger connection detection, battery connection/disconnection detection, maintenance hatch open/close detection, door lock status detection, and key insertion detection. OMRON's D2□W series are dustproof and waterproof (equivalent to IP67*11) microswitches that are available in a wide range of products for various applications. Select the optimum product for your application in terms of load capacity, stroke, mounting type, terminal shape, etc.
*11 Protrusions not included
For object movement and position detection applications
-- D2□W series
[Miniaturization] To minimize the detection mechanism and add functions in a small space
D2EW
No lever needed! "Onigiri-shaped switch" for multi-angle operation
Small microswitch for operation from the top, left, and right minimizes the detection mechanism.
Note: Dimensions are in mm (typical value)
[Safety] To add functions of normal system operation verification/anti-theft/early identification of failure modes
D2AW-R/D2EW-R
Detection of four states by internal resistor Long stroke sealed switch.
Four states (switch ON/OFF, short circuit, open circuit) are output.
Note: Dimensions are in mm (typical value)
[Design simplification] To make mechanism design easier
D2QW
Easy design with long operating stroke!
・2.7 mm without lever, 3.5 mm with lever*12
・Lever shape modification according to the application is also possible.
Note: Dimensions are in mm (typical value)
*12
The OT (movement after operation) value is the distance from OP (operating position) to TTP (operation limit position).
It depends on the type of lever.
Please contact us for lever shapes that are not included in the models.
(Informative) OMRON's main lineup of sealed microswitches (by rated load and stroke)
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Note:
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・Rated load is for resistive load.
・The OT (movement after operation) value is the distance from OP (operating position) to TTP (operation limit position). The above is for those without a lever. (D2FW-G is a leaf lever model)
・We will consider modifications for specifications not listed in the catalog. Please contact us.
Note: If you are considering using them for automotive applications, please refer to the Automotive Switches web page.
4. Recommended products by application
We can offer a wide range of product lineup for various types of electric mobility. Other OMRON products not mentioned above are also available for your consideration.
Electric mobility examples
Electric cart
Electric wheelchair
Electric agricultural machinery
Electric construction machinery
Electric bicycle
Delivery robot
Robot cleaner
AGV
Electric scooter
Electric forklift truck
Note: You need to confirm legal requirements for electric mobility.
Please contact us to discuss your requirements for components.
● Battery management
・Emergency interruption (DC)
Link to detail page: G9EA, G9EC, G9EH, G9EK-1, G9EK-1-E
・Precharge application (DC)
● Various control applications (for PCB-mounted relays)
・Motor control: Power seat, etc.
・Fan control: Blower fan, etc.
・Heater control: PTC heater, etc.
・Lamp control: Headlamp, position lamp, etc.
● Controls/input devices
Speed control, direction change detection, grip detection, key cylinder detection, parking brake detection
* We also support the selection of components for equipment and applications other than those listed above. Please contact us for more information.
Contact Us
Related Contents
Precautions
Please read the following information carefully if you are considering using the product for automotive applications.
Note for sale of Automotive relays/switches and using catalogue
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Selling for car makers and companies related to Automotive
Omron and car makers or companies related to automotive confirm relay specifications and actual using condition to use relays and switches safely. Tests are included when necessary.
Omron can not sell or guarantee our automotive relays and switches when we have not finished making contracts with Product Specification. -
Selling for NO car makers or companies NOT related to automotive, and individual customers
Basically, Omron can not sell our automotive relays and switches for NO car maker or companies NOT related to automotive. Omron basically can not support for individual customers.
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Safety Precautions for All Automotive relays/switches
When you consider using our automotive relays/switches or see our catalogue, please confirm our Common Precautions in advance.
Link for Safety Precautions for All Automotive Relays
DC Power Relay Common Precautions
Link for Safety Precautions for All Detection Switches
Link for Safety Precautions for All Tactile Switches
