Connectors and Sensors for Heavy Equipment and Off-Highway Vehicles

By Stuart Cording for Mouser Electronics

Published June 4, 2026

Noise, exhaust fumes, and dirt: These are what spring to mind when thinking about building and construction sites. And, looking at these monster machines, it’s challenging to imagine it ever being different. Surely earth movers and excavators will be forever dependent on fossil fuels to perform their tasks? But the reality is different. Much like the automotive and haulage industries, these machines, which move tonnes of dirt each day, are also being electrified.

Can an Excavator Be Battery-Powered?

China is particularly focused on the benefits of electrifying heavy equipment. Their China IV regulation update in 2022 builds on existing tailpipe emissions for non-road vehicles, meaning that, today, the use of diesel-powered machinery is essentially prohibited at urban construction sites (Figure 1).^[1]

Figure 1: Tight tailpipe regulations in China mean such building sites typically operate using electrified construction equipment. (Source: Roman Babakin/stock.adobe.com)

And we’re not just talking about the lightweight bits of equipment. As highlighted by EV Magazine, electric options start with smaller machines such as the Bobcat E10e mini excavator and the Avant E Series loader. But then there is Komatsu’s PC210E, a 24-tonne excavator featuring a 123kW electric motor with a lithium-ion battery that supports eight hours of operation, matching the performance of their conventionally powered excavator.^[2]

Need for Connectors and Connectivity Is Growing

Much like in the automotive sector, the move to electrification means more connectors are required. Additionally, more data is flowing through this equipment, and support for wireless systems, such as GPS, remote monitoring, and remote control, is being added, enabling new modes of operation on construction sites.

What’s not changed are the environmental conditions. Mud, dirt, and dust accumulate throughout the day, so connectors must withstand high-pressure washing and the chemicals used during cleaning.

For electrified heavy-equipment applications, such as the high-power paths between batteries, inverters, power distribution units (PDUs), pumps, and drives, Amphenol provides the TS1 Series High-Current eMobility Power Connector. This single-pole connector is engineered for high voltage DC systems up to 2,000V and continuous 450A operation (600A for 15 minutes) using the 12.0mm interface, or 350A with the 8.0mm variants (Figure 2). IP6K9K, IP67, and IP68 sealing is supported when mated, offering ingress protection during cleaning. 500 hours of salt spray resistance is specified, and the connector is 20G vibration-rated at the rated current.

Figure 2: Amphenol Industrial TS1 Series high-current eMobility power connector. (Source: Amphenol Industrial)

The metal shell provides 360° EMI shielding, while N, W, X, Y, and Z keying ensure a secure connection to the correct cable. Optional copper high-voltage interloop lock (HVIL) contacts can be used for functional safety and to implement safe power-down during servicing or emergency responder access, and the series is also IP2XB touch-protected.

Robust Connectivity on Construction Sites

With the growth in vision systems and sensors, connectors are needed that handle power and data while also being robust and easy to connect and disconnect for servicing. In this case, Amphenol LTW X-Lok Push Lock connectors should be considered (Figure 3). These robust, metal connectors build upon the existing plastic series, in some cases offering an alternative to M12 connectors that fit in the same panel cut-out.

Figure 3: Supporting power, data, and signals, the LTW X-Lok series provides blind mating and IP68 protection. (Source: Amphenol LTW)

With protection up to IP68, this spring-loaded push design is quicker to install than traditional threaded designs and supports blind mating with audible and tactile feedback. The mini-size variants provide ultra-high-density pinning with up to 33 contacts, a rating of 30V and 0.5A, and can withstand 1,000 connection cycles and 48 hours of salt spray. In addition to plugs, sockets, and complete cable assemblies, waterproof caps with rubber leads are available.

In some cases, a complete receptacle block is required that brings connectivity together in a single location. Amphenol Sine Systems’ HYPERBUSS PSM Bussed Receptacle Blocks (Figure 4) do just this, being compatible with standard AT, ATP, ATHD, and AHDP series plugs and cable assemblies.

Figure 4: Meeting the SAEJ1939 requirement and capable of handling up to 220V and 225A, the PSM receptacle blocks are ideal for heavy industry and agricultural vehicles. (Source: Amphenol Sine Systems)

Designed for heavy industry, transportation, marine, and agricultural use, their potted blocks and sealed connections prevent the corrosion found on open screw bus bars, meeting IP68 and IP69K ratings when mated. The PSM receptacle blocks integrate latches for proper mating with their respective plugs and other industry-standard connectors. On the power side, the block can operate at up to 220V with a maximum current rating of 13A to 225A. When it comes to data, the blocks meet the SAEJ1939 requirement for CAN bus applications.

Antennas for Wireless Data and Sensors

On the wireless front, SMA connectors remain a reliable option for attaching antennas or coaxial cables. Amphenol RF’s SMA Coaxial Connectors (Figure 5) offer low VSWR performance for reliable impedance matching and signal integrity. With exceptional performance up to 26.6GHz, these threaded 50Ω impedance connectors provide PCB, cable, and panel mounting, offering flexibility to suit any application.

Figure 5: The classic SMA coaxial connector offers RF connectivity that is equally at home on a PCB, at the end of a cable, or for panel mounting. (Source: Amphenol RF)

Data collection in this space demands a robust sensor capable of delivering accurate and reliable continuous output. The GE-209x Pressure and Temperature Combination Sensors (Figure 6) are well-suited for the rigours of heavy equipment, enabling simultaneous measurement of both pressure and temperature.

Figure 6: These robust GE-209x pressure and temperature sensors are ideal for electric vehicle battery coolant monitoring. (Source: Amphenol Advanced Sensors)

These sensors integrate an Amphenol Advanced Sensors NTC thermistor, known for its exceptional stability, with a highly sensitive MEMS absolute pressure die. This combination provides a reliable and effective solution for continuous system monitoring.

The housing is available in either stainless steel or brass, allowing for easy selection based on chemical compatibility. The pressure measurement range spans 0.2 to 6.55 bar, with an operating temperature range of −40°C to +135°C, making the sensor ideal for demanding applications such as electric vehicle (EV) battery coolant monitoring.

Remaining Robust While Staying Connected

There is no doubt that the landscape of the heavy vehicle industry is changing. In some regions, legislation and financial incentives are pushing the move away from diesel-powered equipment. But in many cases, it is the attractive total cost of ownership (TCO) that is drawing customers in, with 50 percent savings in energy costs and simpler, less costly servicing. What isn’t changing is the expectation of the tasks that equipment should perform and the conditions under which it operates. Rugged, reliable connectors and sensors help manufacturers achieve long-term reliability, simplify servicing, and enable digital services and support of remote operation.

Sources

[1] https://theicct.org/publication/the-updated-china-iv-non-road-emission-standards/
[2]https://evmagazine.com/top10/top-10-electric-construction-vehicles

Stuart Cording is “The Electronics Reporter”—an engineer turned influencer dedicated to helping the electronics community make sense of today’s complex technologies. With 30 years of experience in semiconductors and embedded systems, he uncovers the stories, insights, and practical know-how that help engineers solve real design challenges. Through articles, podcasts, and videos, Stuart connects innovators, shares technical wisdom, and celebrates the people driving progress in deep tech.