WE CONNECT THE E-POWERTRAIN
High-voltage cable assembly for mobile and industrial applications
From prototype cables to mass production – reliable high-voltage connections
Partner for large and small batches in high-voltage cable production
We assemble high-voltage connectors and high-voltage cables according to the VDA standard, which safely transmit the corresponding currents and control the applied voltages.
The production of prototypes in small quantities up to 50 pieces is just as much a part of our day-to-day business as series production in large numbers. We therefore rely on the low volume high mix. In cooperation with the customer, we develop individual solutions if no samples are available yet. Components from well-known manufacturers such as Amphenol or Hirschmann are used for high-voltage cable assembly. Finally, the high-voltage assemblies are checked using a fully automatic high-voltage tester (quality assurance of the HV components).
Assemble HV cables
Combine high-voltage connector systems and high-voltage cables from different manufacturers according to your needs. Whether as a “pigtail” or a pre-assembled cable set.
Our services - your advantages
We assemble cables for the on-board network of various commercial and transport vehicles. Our clients benefit from expert advice and the complete design of the high-voltage cabling. We also take on the serial production of cabling systems for rough areas of application.
- Production according to VDA guidelines, tests according to LV 123
- Sample deliveries in a short time
- Fast reaction times
- Processing of cables from the brands Huber + Suhner, Coroplast, LEONI or other brands according to your specifications up to cross-sections of 120 mm² and a temperature resistance of up to 180°C
- Processing of HV-connectors with IP67 / IP6k9k, for a temperature range from -40° C up to 140° C and for currents up to 750 A / 1,000 V in different embodiments
- 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 connector systems according to the VDA standard. For applications such as a 3-phase drive train or a 2-pole battery pack, accessories are available for conductor sizes 25, 35, 50, 70, 95 and 120 square millimeters, as well as an application for shield crimping. Cross-sections of 2,5 to 16 square millimeters 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.
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 modules can be designed as a so-called pigtail variant attached on one side or as a finished, double-sided version - also with different connector systems. Pigtails are partial assemblies. We also take care of the complete cabling and the production of individual components such as Power Distribution Units. 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.
Suitable shielding prevents the emission of electromagnetic waves (EMC). The complex systems are exposed to high thermal and mechanical loads and must be temperature, weather and aging resistant.
High-voltage cable assembly for prototypes, pre-series and stable mass production
We support your project from the first prototype cable through pre-series production to stable series production. In doing so, we lay the groundwork to ensure that an initial solution develops into a robust series production process – with defined procedures, coordinated variants and reproducible manufacturing quality.
Particularly with complex high-voltage connections, it is crucial not to view prototypes in isolation, but to think in terms of series production from an early stage. That is why we provide support right from the development phase in designing customer-specific solutions, even when no samples are yet available, and systematically translate suitable concepts into pre-series and series production.
- Samples, prototypes, pre-series and series production from a single source
- Scalable production for varying batch sizes
- Defined manufacturing and testing processes for consistent quality
- Variant management for different connector and cable combinations
- Customised development as the basis for a reliable transition to series production
Quality assurance of the HV components
Before delivery, the high-voltage assemblies are tested using 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.
Cable assembly in the high-voltage and 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. in-Tec Bensheim develops holistic cabling solutions for your project.
