Amphenol Introduces Floating Mate Connector Series for Modular Energy and Power Systems
Amphenol Industrial Operations has announced the launch of its new Floating Mate Connector Series, a compact, high-current hybrid interconnect solution designed to meet the evolving demands of modular battery systems and electrified power platforms. Engineered specifically for applications where battery drawers, slide-in power shelves, or serviceable energy modules must connect reliably at the rack or cabinet level, the new connector series addresses a growing industry need for efficient, repeatable, and service-friendly power and signal interfaces.
As energy storage systems (ESS), data center power architectures, industrial electrification, and transportation platforms continue to push toward higher power densities, system designers face increasing mechanical and electrical challenges. Equipment footprints are shrinking, yet voltage and current requirements are rising. In response, many manufacturers are shifting away from permanently wired assemblies toward modular, replaceable subsystems that can be installed, removed, or serviced with minimal disruption. Amphenol’s Floating Mate Connector Series is purpose-built to support this modular design philosophy.
Supporting the Shift Toward Modular Architectures
Across energy storage and electrified infrastructure, modularity has become a central design strategy. Battery drawers and slide-in modules enable faster assembly during manufacturing, easier scalability in the field, and reduced downtime when maintenance or upgrades are required. Instead of rewiring or disassembling entire cabinets, technicians can replace individual modules, restoring system operation quickly and efficiently.
However, this approach places new demands on the interconnection interface. Traditional plug-and-cable solutions often struggle to deliver consistent performance in drawer-style or blind-mate applications. Mechanical misalignment, tolerance stack-up across rails and frames, and restricted access inside cabinets can complicate installation and increase the risk of damaged connectors or incomplete mating.
The Floating Mate Connector Series is engineered to overcome these limitations. By using a floating engagement mechanism, the connectors accommodate minor misalignments during insertion, enabling consistent blind mating without requiring precise manual alignment. This design improves assembly repeatability, reduces installation time, and helps ensure long-term reliability across repeated insertion and removal cycles.
Addressing Assembly and Service Challenges
In many rack- and cabinet-based systems, the connector interface becomes a bottleneck for both manufacturing efficiency and field serviceability. Dense harnessing, limited internal space, and awkward access points often force technicians to manage multiple separate connections for power, control, sensing, and grounding. This increases the likelihood of wiring errors and prolongs service times.
Amphenol’s Floating Mate Connector Series consolidates these connections into a single hybrid interface, significantly simplifying both initial build and ongoing maintenance. By integrating high-voltage power contacts and low-voltage signal positions within one connector body, the series reduces overall connector count and streamlines cable routing inside the enclosure.
For manufacturers, this translates into faster assembly processes, cleaner cabinet layouts, and improved standardization across product lines. For operators and service teams, it means fewer connection points to manage, quicker module swaps, and reduced risk of incorrect reconnections during servicing.
Hybrid Power and Signal Integration
Modern battery drawers and power modules rarely operate as standalone components. In addition to main DC power paths, they require low-voltage connections for monitoring, communication, control, and safety functions. Voltage sensing, temperature monitoring, battery management system (BMS) communications, and interlock signals all rely on dependable low-voltage signal paths.
The Floating Mate Connector Series addresses this requirement by combining high-current power contacts with multiple low-voltage signal contacts in a single connector. This hybrid design ensures that both power and data connections are established simultaneously during module insertion, supporting reliable system operation from the moment a drawer is seated.
By reducing the need for separate signal connectors or auxiliary harnesses, the hybrid interface helps designers optimize limited cabinet space and improve airflow. It also enhances layout consistency, making it easier to replicate designs across different cabinet sizes or power ratings.
Proven Contact Technology for High-Current Performance
At the core of the Floating Mate Connector Series is Amphenol’s proven RADSOK® contact technology, which is widely used in high-current and high-reliability applications. RADSOK technology employs a radial contact design that increases the effective contact surface area, resulting in lower electrical resistance and improved current-carrying capability.
The series supports up to 120 amps per power contact, enabling it to handle demanding power requirements in modern ESS and electrified platforms. Depending on the configuration, the connectors are suitable for system designs operating in the 1,000 to 1,500 VDC range, aligning with the higher voltage levels increasingly adopted to improve efficiency and reduce conductor size.
Available layouts include 2+12, 4+12, and 4+12 Mini configurations, offering designers flexibility to balance power and signal needs based on specific application requirements. This modularity allows the same connector family to be used across multiple system variants, simplifying procurement and qualification processes.
Designed for Safety and Compliance
Safety remains a critical consideration in high-voltage energy systems, particularly in applications involving frequent module insertion and removal. The Floating Mate Connector Series incorporates several features designed to enhance operator safety and support compliance with relevant standards.
The power interface is finger-proof (IP2XB), helping prevent accidental contact with live conductors during handling or servicing. This is especially important in field environments where technicians may be working under time pressure or in confined spaces.
Additionally, the connector includes first-mate/last-break contact positions, which can be used for grounding or interlock-style functions. These contacts ensure that safety-related connections are established before power contacts engage and are maintained until after power is disconnected, reducing the risk of arcing or unsafe conditions during mating and unmating.
Improving Reliability Over the Product Lifecycle
Repeated insertion and removal cycles can place significant mechanical and electrical stress on connector systems. Poorly designed interfaces may loosen over time, degrade electrically, or become damaged due to misalignment. The floating engagement mechanism used in Amphenol’s connector series helps mitigate these issues by absorbing mechanical tolerances and reducing mating forces.
By allowing controlled movement during engagement, the connectors minimize wear on contacts and housings, supporting consistent electrical performance throughout the product lifecycle. This durability is particularly valuable in applications such as grid-scale energy storage, telecom power systems, and industrial electrification, where uptime and reliability are paramount.
Enabling Scalable and Serviceable Energy Systems
As energy infrastructure continues to evolve, scalability and serviceability are becoming as important as raw electrical performance. Operators expect systems that can be expanded, upgraded, or repaired without extensive downtime or specialized labor. Connector solutions play a critical role in enabling this flexibility.
The Floating Mate Connector Series aligns with these expectations by supporting tool-less or minimal-tool servicing, reducing the number of manual steps required to replace a module. Its standardized hybrid interface also simplifies training for service personnel, as the same connection approach can be used across different system configurations.
Applications Beyond Energy Storage
While the connector series is well suited for battery energy storage systems, its design principles extend to a broader range of electrified platforms. Applications may include data center power distribution, renewable energy inverters, industrial power supplies, rail and transportation electrification, and other environments where high-current modular power connections are required.
In each of these applications, the need for reliable blind mating, compact form factors, and integrated power and signal connectivity continues to grow. Amphenol’s solution addresses these trends by combining mechanical flexibility, electrical performance, and safety into a single connector family.
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