WE CONNECT THE E-POWERTRAIN
High-voltage on-board network
We create safe and future-oriented
connections in vehicles
connections in vehicles
High-voltage electrical system in electric cars
The high-voltage on-board network is complex and the distribution of power in the vehicle electrical system requires specialist knowledge and experience. We support companies and suppliers from the automotive and commercial vehicle industries. Depending on the customer's requirements, we deliver the right result for secure connections in the vehicle network. The in-Tec Bensheim team takes care of the greatest possible security and the distribution of energy with low losses.
Topic Areas
High-voltage on-board network ➞
Pigtails ➞
On-board network development ➞
High voltage plugs ➞
Electric ships ➞
Prototype construction ➞
Electrification boats and ships ➞
Stationary energy storage ➞
High voltage for autonomous vehicles ➞
Cable assembly for Bosch drives ➞
Military applications ➞
High-voltage systems for port logistics ➞
Our services high-voltage on-board network
We offer solutions that convince and support your company where it is needed. Our services for all aspects of the high-voltage on-board network at a glance:
- Concepts for HV cabling in electric vehicles
- Assembly of HV cabling
- PDU - Power Distribution Unit for high-voltage use
- Production of on-board charger lines
- Manufacture of battery module connectors
- Measurement boxes (BreakOut boxes) for the high-voltage area
Here on our website you will find further details on the solutions for all aspects of the high-voltage on-board network.
Find out more about our high-voltage services and products for various industries ➞
Find out more about our high-voltage services and products for various industries ➞
What is the high-voltage electrical system?
High voltage is meant when systems in motor vehicles are operated above 25V AC / 60V DC. The system components in the vehicle electrical system must work in the specified voltage range in every driving situation.There are numerous security requirements to be observed. Factors such as contact protection, mechanics and installation guidelines play decisive roles in the operation of the HV on-board network.
All components in an electric vehicle and their interconnection make up the high-voltage on-board network. On-board network components are, for example:
All components in an electric vehicle and their interconnection make up the high-voltage on-board network. On-board network components are, for example:
- Plug
- Cable
- Battery
- PDU
- Breakout Box
- On-board charger
High-voltage on-board network - Partner for power distributors and components
In-Tec Bensheim is characterized by development and manufacturing expertise. We deliver a tailor-made solution for high-voltage environments in vehicles. We develop, manufacture and deliver high-voltage electrical systems for our customers. Each customer receives individual advice and support. We design and manufacture and concept electrical systems and components not only for purely electric vehicles. Secure our competence also for hydrogen fuel cell drives and fuel cell vehicles.
Equipment for working in the high-voltage electrical system
Various test options are available to us for quality assurance of the high-voltage connections and components. The fully automatic high-voltage tester with 2650 VAC / 3750 VDC and the single test station up to 6 KV AC for prototype development. The HV components are checked in accordance with delivery specification 123. Regular process audits by our partners examine our manufacturing processes for the necessary smoothness and efficiency.
The high-voltage cable assembly requires precision and strength. The machine park optimally supports our specialists.
The high-voltage cable assembly requires precision and strength. The machine park optimally supports our specialists.
- For applications (drive train, battery train): Accessories for conductor sizes 25, 35, 50, 70, 95 and 120 square millimeters
- Application for shield pressing
- For the charging line and peripheral devices: cross-sections from 2.5 to 16 square millimeters
- Hydraulic presses (HV crimp press) with a capacity of up to 15 tons and an eccentric press with 20 tons of pressing force.
- Hand hydraulic tools depending on requirements
Cabling in the on-board network with branded products
We focus on quality and care. We obtain plugs and cables from experienced manufacturers such as TE Connectivity, Huber & Suhner, Hirschmann, Amphenol and many others. We can offer our customers the best possible quality for every area of application.
Connector manufacturer
We use products from TE Connectivity, Amphenol and Hirschmann for our tailor-made high-voltage solutions.
More about plugs and plug manufacturers ➞
Cable gland manufacturer
We use cable glands from AGRO for safe processes.
More about cable gland manufacturer ➞
Cable manufacturer
We trust in brand manufacturers such as Coroplast, Coficab, Helutherm, HEW Kabel, Huber + Suhner, Kromberg & Schubert and Silitherm.
We trust in brand manufacturers such as Coroplast, Coficab, Helutherm, HEW Kabel, Huber + Suhner, Kromberg & Schubert and Silitherm.
We meet customer requirements
In addition, we can create almost any desired combination for high-voltage vehicle electrical systems, even if these are not explicitly listed on our manufacturer's website.
In addition, we can create almost any desired combination for high-voltage vehicle electrical systems, even if these are not explicitly listed on our manufacturer's website.
