As electric vehicle technology evolves, the demand for reliable, high-voltage connections continues to rise. High Voltage Interlock Loop (HVIL) connectors are essential components that ensure safe energy transfer and interlock integrity within every HVEV system.
At Aeromotive, we specialize in wire harness assembly and connector integration for today’s most demanding EV applications — from traditional automotive to next-generation electrified platforms.
Understanding HVIL Connectors
An HVIL (High Voltage Interlock Loop) is a safety feature designed to detect disconnections or faults within a high-voltage circuit. It ensures that power is automatically cut when the system detects a break, preventing electric shock and safeguarding technicians, vehicles, and components.
Key Connector Classification Criteria:
Terminal type and structure
Locking and secondary unlocking mechanisms
Shielding and TPA (Terminal Position Assurance) systems
Compliance with TE Connectivity and OEM specifications
Generational Progress: From Industrial Use to SMART HVIL
High-voltage connectors have undergone major evolution to meet modern EV requirements:
1st Generation: Industrial Use – Basic high-voltage power transfer
2nd Generation: Interlock Loop – Introduced HVIL safety circuits
3rd Generation: Shielding – Enhanced EMI protection and voltage stability
4th Generation: SMART HVIL – Adds secondary safety and communication layers
Each generation has improved not only electrical performance but also assembly integrity, shielding consistency, and diagnostic capability.
TE Connectivity HVP 800 Series: Trusted Performance
Aeromotive’s production process follows TE Connectivity’s HVP 800 180° connector standards — precision-engineered systems featuring:
2- and 3-position shielded connectors
Cable compatibility: 16–50 mm²
Compliance: LV216-2 and ISO 19642-9
Integrated lever locking and CPA safety mechanisms
Reliable shielding and interlock continuity
ENG_SS_114-94130_G6
Our quality-driven assembly ensures consistent electrical characteristics, verified through final examination and visual inspection to TE-108-94297 specifications.
Aeromotive’s Expertise in High-Voltage Systems
Our manufacturing team brings together decades of connector assembly experience with advanced testing and validation to meet the needs of today’s electrified platforms. From prototype to production, Aeromotive ensures:
Precise terminal crimping and shielding
Compliance with global automotive standards
Consistent cable integrity and sealing performance
Ongoing quality verification through our QMS
Watch the Video
See Aeromotive’s Carl Dumele explain how our high-voltage (HV) and high-voltage interlock loop (HVIL) connector assemblies are powering the future of electric mobility.
From shielding and secondary locking to TE Connectivity compliance, Carl walks through what makes Aeromotive’s HVP 800 Series assemblies stand out for precision and safety in every HVEV application.
👉 Watch the video below to learn more about our process and commitment to quality.
At Aeromotive, Quality Connects Us® — and it drives our commitment to innovation in HVEV connectivity.
🔗 Contact us today to learn how our high-voltage connector assemblies can power your next-generation electric systems.
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