EV Automotive High Voltage DC Relay
High Current DC Relay
Our high-voltage pre-charge relays are electromechanical devices designed to switch high voltage loads. These relays operate in the same way as electromechanical relays with the addition of features that allow these to be used in high voltage applications like battery disconnect units (BDU) and charging systems supporting the future of mobility. All of our automotive relays and contractors comply with the demanding switching requirements of hybrid and electric vehicles.
An EV car high voltage DC relay is an electrical component used in electric vehicles to control the flow of high voltage direct current (DC) power between the battery and various components of the vehicle, such as the motor and the charging system.
The high voltage DC relay typically consists of a coil, contacts, and a housing. When a voltage is applied to the coil, it generates a magnetic field that pulls the contacts together, allowing the flow of current through the relay. When the coil is de-energized, the contacts open, interrupting the flow of current.
In an electric vehicle, the high voltage DC relay is typically used to control the flow of power from the battery to the motor and other components. For example, when the driver presses the accelerator pedal, the high voltage DC relay closes, allowing the current to flow to the motor, which then turns the wheels. When the driver releases the pedal, the relay opens, cutting off the power to the motor.
The high voltage DC relay is an essential component of an electric vehicle’s electrical system, and it must be designed to handle the high voltages and currents that are typically involved in an electric vehicle’s powertrain.
Ceramic Brazing seal
Rectangular EVM Series
Ceramic Brazing seal, No arc leakage; helps prevent fire and burst risk, The insulation resistance reaches 1000MΩ（1000VDC） and meets the requirements of IEC60664-1
Product Features
Coil Voltage: 12VDC 24VDC
Current: 40A 100A 200A 300A 400A
Voltage: 450VDC 750VDC
Silence
Compact structure, low noiseÂ
Safe
The mixed gas mainly filled with hydrogen can prevent the contact from oxidation and burnÂ
High Current
40A 85℃ long time current carrying capacityÂ
special epoxy seal
Cylindrical EVI Series
Special Epoxy seal, No arc leakage, protection class IP68, Helps prevent arc leakage, fire, and burst risk, The insulation resistance reaches 1000MΩ（1000VDC） and meets the requirements of IEC60664-1
Product Features
Coil Voltage: 12VDC 24VDC
Current: 40A 100A 200A 300A 400A
Voltage: 450VDC 750VDC
Silence
Compact structure, low noiseÂ
Safe
The mixed gas mainly filled with hydrogen can prevent the contact from oxidation and burnÂ
High Current
40A 85℃ long time current carrying capacityÂ
Automotive DC Relay
Customized Relays can be provided
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Technical Diagram and Sourcing Notes
This diagram shows high-voltage DC relay contact structure and terminal references for electric vehicle and industrial applications.
Technical guide and buying support
Use this EV DC relay guide to review application basics, selection criteria, and high-voltage switching considerations.
EV DC Relay selection checklist
High-voltage relay sourcing requires voltage, current, coil, contact form, and application details before quotation.
Selection checklist
- Rated voltage and continuous current
- Coil voltage and contact configuration
- Load type: EV, battery, charger, solar or industrial system
- Mounting, terminal style and safety requirements
Common symptoms
- Relay does not close or open reliably
- Contact overheating or welding
- Pre-charge / main contactor fault
- Insulation or abnormal noise issue
What to send for RFQ
- Electrical rating and coil voltage
- Application and load type
- Quantity and sample testing plan
Buyer FAQ
What ratings are needed for a DC relay quote?
Voltage, current, coil voltage, contact form, load type, and quantity are the minimum details for accurate relay sourcing.
Can one relay model replace another directly?
Only when electrical rating, contact form, mounting, terminals, and safety requirements match the application.
Related technical resources
EV DC relay application and selection resources
Review relay function, current/voltage requirements, and EV application basics before choosing a relay series.
EV DC Relay Guide: Function and Selection Tips
Application basics and selection tips for high-voltage DC relays.
Read guideHigh-Voltage DC Relay Q&A for Electric Vehicles
Common questions about DC relays in EV battery and charging systems.
Read guide