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High-voltage cable configurator

Configure and order your preferred high-voltage cabling now.

Assembly of high-voltage cables for electric vehicles

in-Tec Bensheim has specialised in high-voltage connectors and high-voltage cables according to the VDA standard, which safely transmit the corresponding currents and control the applied voltages.

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Partner for large and small batches in high-voltage cable production

Low Volume High Mix: The production of prototypes in small volumes of up to 50 pieces is as much part of our daily business as is serial production in large volumes. In cooperation with the customer, we develop individual solutions if samples are not yet available.

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Our Services and Your Benefits

  • Expert advice and complete conception of high-voltage cabling
  • Series-ready production of cabling systems - also for harsh application areas
  • Production according to VDA guidelines Tests according to LV 123
  • Sample deliveries in a short time
  • Rapid response times
  • Processing of cables belonging to the Huber + Suhner, Coroplast, LEONI or other brands, aligned to your specifications and up to cross sections of 120 mm² with a temperature resistance up to 180° C
  • Processing of HV connectors with protection class IP67 / IP6k9k, for a temperature range from -40° C up to 140° C and for currents up to 750 A / 1,000 V in various versions
  • Documentation plans of the cabling concept for follow-up orders
  • Material procurement and stockpiling

Our Equipment for Certified Quality

Our equipment guarantees the development, production and monitoring of high-voltage plug systems in line with VDA standards. For applications such as a 3-phase drive train or a 2-pole battery train, accessories are available for conductor sizes 25, 35, 50, 70, 95, and 120 square millimetres, as well as an application for shield crimping. Cross-sections of 2.5 to 16 square millimetres are possible for the charge train and peripheral devices.

We work on two press systems: hydraulic presses (HV crimp press), with a capacity of up to 15 tons and an eccentric press with 20 tons press force. This equipment also allows crimping with corresponding crimping dies from 120 to 400 square millimetres, for predominantly unshielded cables. The tool geometry ranges from hexagonal to semi-circular with a dimple to WM shape.

Pigtail or Complete System

The high-voltage assemblies can be designed as a so-called pigtail version, attached on one side, or as a finished version on both sides - also with various connector systems. Versions with pilot contacts (High Voltage Interlock) can be equipped with customer-specific lines and terminals in the inliner as well as on the header.

A suitable shielding prevents the emission of electromagnetic waves (EMC). The complex systems are exposed to high thermal and mechanical stress and must be resistant to temperature, weather and ageing.

Quality Assurance of the HV Components

Prior to delivery, the high-voltage assemblies are tested by a fully automatic high-voltage tester with 2650 VAC/3750 VDC.

The production of safe high-voltage cabling concepts is a challenge that requires a high degree of experience. Individual connectors and cable requirements are also defined in the delivery specifications of the German car manufacturers LV214, LV215 and LV216. The US-Car 2 and US-Car 37 specify the requirements for the North American market.

Cabling in the Low-Voltage Range

As a specialist in cable assembly, it goes without saying that we also ensure secure cable connections in the low voltage range. Be it the assembly of cable harnesses for the LV-board network or the HV-control units. We develop integrated cabling solutions for your specific project.

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Send us an enquiry now

Do you already have a detailed plan? Then use our HV cable configurator and put together your cable sets individually.

Configure a high-voltage-line

You need advice and want to know more about our services? Call us or use our contact form.

feel free to contact us