EV High Voltage Relays - Global Industry Market Analysis Report 2020-2031

The high-voltage relay of electric vehicles is a control element specially used in the high-voltage circuit system of electric vehicles. It is mainly used to realize the on-off control of high-voltage circuits and is a key component to ensure the high-voltage safety of electric vehicles. In the electrical architecture of electric vehicles, high-voltage relays play an important role like circuit switches, and their performance directly affects the safety, reliability and overall operating efficiency of the vehicle.

From the working principle, the high-voltage relay of electric vehicles is mainly composed of coils, armatures, contacts, arc extinguishing chambers, springs and shells. When the coil is energized, a magnetic field is generated to attract the armature to move, so that the contacts are closed, thereby connecting the high-voltage circuit; when the coil is de-energized, the magnetic field disappears, the armature is reset under the action of the spring, the contacts are disconnected, and the high-voltage circuit is cut off. Since a high-temperature and high-voltage arc is generated in the process of cutting off the high-voltage circuit under load, this will not only damage the contacts of the relay, but also cause the contacts to stick together. In severe cases, it may even cause the relay to explode, endangering the safety of the vehicle. Therefore, the contacts of the on-board high-voltage DC relay are generally placed in the arc extinguishing chamber. Vacuum, hydrogen or other mixed gases are often used as insulating media in the arc extinguishing chamber. Hydrogen can effectively prevent contact oxidation due to its reducing properties, and its excellent thermal conductivity helps to reduce the temperature rise of the contacts when the arc is generated and protect the contacts. At the same time, the arc extinguishing chamber is usually combined with electromagnetic arc blowing to further enhance the arc extinguishing ability. However, it should be noted that some relays have positive and negative high-voltage contacts. If the positive and negative high-voltage contacts are connected in reverse during use, the load-cutting ability of the relay will be reduced.

In terms of functional characteristics, electric vehicle high-voltage relays have multiple key performance indicators. In terms of coil parameters, the rated working voltage is usually divided into 12V and 24V, and it needs to be selected according to the specifications of the vehicle control power supply. Relays of different specifications have differences in their operating voltage, release voltage, coil resistance and power consumption. At present, the commonly used relays on the market, whether 12V or 24V specifications, basically do not exceed 6W in coil power consumption. The coil resistance of 12V specifications is generally about 24Ω, and the coil resistance of 24V specifications is about 96Ω. In terms of contact parameters, current overload capacity, electrical life and maximum breaking current are the key factors to consider when selecting and matching. Current overload capacity refers to the time that the relay can be normally powered on under certain current conditions. During the driving process, the vehicle will have short-term high current conditions, such as accelerating and overtaking, which requires the relay to not only meet the rated current conditions, but also be able to withstand short-term overload current. Electrical life refers to the number of times the relay contact can be switched on and off under the corresponding current. For example, during the high-voltage power process of the power battery, there is still a voltage difference between the capacitor and the battery after the pre-charge is completed. When the main positive relay is closed, hundreds of amperes of current will pass through. Therefore, it is necessary to evaluate whether the electrical life of the relay meets the requirements based on the number of power-on and power-off times during the entire life cycle of the vehicle. The maximum breaking current refers to the maximum current that the relay can normally cut off. When the vehicle is short-circuited, the relay must be able to cut off normally once under signal control to ensure safe disconnection of high voltage and ensure the electrical safety of the vehicle. In terms of application scenarios, electric vehicle high-voltage relays are widely used in various high-voltage circuits of electric vehicles. In the main power circuit, it is used to connect the high-voltage battery system and the traction inverter to control the power output of the vehicle; in the charging circuit, it is used to connect the charging station and the battery to realize the on-off control of the charging process; in addition, it is also used in the auxiliary circuits of other electrical loads such as interior lights and heaters. For example, when the vehicle is charging, the high-voltage relay controls the connection and disconnection of the charging circuit to ensure the safety and stability of the charging process; when the vehicle is driving, the high-voltage relay in the main power circuit switches the circuit on and off in time according to the operating status of the vehicle to provide power for the vehicle.

When selecting, in addition to considering the above-mentioned coil parameters and contact parameters, attention should also be paid to the structure and technical parameters of the use environment of the relay. Its appearance size and layout must be compatible with the spatial layout of the vehicle; the sealing must meet the waterproof and dustproof requirements of the vehicle in different environments; the use temperature, humidity, pressure range and mechanical conditions must be able to adapt to the actual use scenarios of the vehicle to ensure stable and reliable operation under various working conditions.

With the continuous development of electric vehicle technology, the performance requirements for high-voltage relays are also continuously improving. In the future, high-voltage relays will develop towards higher voltage and current carrying capacity, smaller size and weight, longer service life and higher reliability. On the one hand, R&D personnel will continue to explore new materials and design technologies to improve the arc extinguishing ability and anti-interference performance of relays to meet the growing high voltage and high current demand of electric vehicles; on the other hand, with the application of intelligent technology in the automotive field, high-voltage relays may also integrate more intelligent control functions to achieve collaborative work with other vehicle systems, further improving the safety and intelligence level of electric vehicles.

Report Scope

This report aims to deliver a thorough analysis of the global market for EV High Voltage Relays, offering both quantitative and qualitative insights to assist readers in formulating business growth strategies, evaluating the competitive landscape, understanding their current market position, and making well-informed decisions regarding EV High Voltage Relays.

The report is enriched with qualitative evaluations, including market drivers, challenges, Porter’s Five Forces, regulatory frameworks, consumer preferences, and ESG (Environmental, Social, and Governance) factors.

The report provides detailed classification of EV High Voltage Relays, such as type, etc.; detailed examples of EV High Voltage Relays applications, such as application one, etc., and provides comprehensive historical (2020-2025) and forecast (2026-2031) market size data.

The report provides detailed classification of EV High Voltage Relays, such as Main Relays, Quick Charge Relays, Others, etc.; detailed examples of EV High Voltage Relays applications, such as BEV, PHEV, etc., and provides comprehensive historical (2020-2025) and forecast (2026-2031) market size data.

The report covers key global regions—North America, Europe, Asia-Pacific, Latin America, and the Middle East & Africa—providing granular, country-specific insights for major markets such as the United States, China, Germany, and Brazil.

The report deeply explores the competitive landscape of EV High Voltage Relays products, details the sales, revenue, and regional layout of some of the world's leading manufacturers, and provides in-depth company profiles and contact details.

The report contains a comprehensive industry chain analysis covering raw materials, downstream customers and sales channels.

Core Chapters

Chapter One: Introduces the study scope of this report, market status, market drivers, challenges, porters five forces analysis, regulatory policy, consumer preference, market attractiveness and ESG analysis.
Chapter Two: market segments by Type, covering the market size and development potential of each market segment, to help readers find the blue ocean market in different market segments.
Chapter Three: EV High Voltage Relays market sales and revenue in regional level and country level. It provides a quantitative analysis of the market size and development potential of each region and its main countries and introduces the market development, future development prospects, market space, and production of each country in the world.
Chapter Four: Provides the analysis of various market segments by Application, covering the market size and development potential of each market segment, to help readers find the blue ocean market in different downstream markets.
Chapter Five: Detailed analysis of EV High Voltage Relays manufacturers competitive landscape, price, sales, revenue, market share, footprint, merger, and acquisition information, etc.
Chapter Six: Provides profiles of leading manufacturers, introducing the basic situation of the main companies in the market in detail, including product sales, revenue, price, gross margin, product introduction.
Chapter Seven: Analysis of industrial chain, key raw materials, customers and sales channel.
Chapter Eight: Key Takeaways and Final Conclusions
Chapter Nine: Methodology and Sources. Show more