e-mobility Special cables for electric vehicles Coroplast Fritz Müller GmbH & Co. KG Tapes Cables Cable Assemblies

Transcription

1 e-mobility Coroplast Fritz Müller GmbH & Co. KG Tapes Cables Cable Assemblies Special cables for electric vehicles Wittener Straße 271 D Wuppertal Phone +49(0) Fax +49(0) /2011 Keeping you connected.

2 Silicone-insulated single-core high voltage automotive cables Application: Connection of HV batteries and electric motors Cable construction according to LV 216-2, ISO 6722 and ISO Construction of HV wiring systems for hybrid and electric vehicles High voltage cable, single-core, shielded FLR2GCB2G, 4 mm² Single-core, shielded automotive cables for high voltage cable sets After several years of development work, it was possible to develop insulation materials which on the one hand can withstand high voltage loads and on the other hand correspond to the high automotive requirements in terms of flexibility and EMC shielding. Operational voltages of up to 600 volts are possible with the Coroplast silicone high voltage cables. Prototype cables for testing the future voltage class of 1000 volts are available. The normative recognition of this voltage class is proactively supported by our company. The very good flexibility of Coroplast high voltage cables is obtained through the simultaneously fine wired and compact cable constructions. Double shieldings with braided wires and metal foils are used because of the high EMC requirements. The current standards and specifications of the OEM (inter alia LV 216) are the basis for this design. Furthermore, customer-specific details such as extruded vertical stripes can be installed. A detailed overview of the construction data of Coroplast HV cables can be found on the internet at: Optimised dimensioning of the cable cross sections Coroplast HV cables are able to permanently withstand temperatures of up to 180 C. This enables an optimisation of the conductor cross section in contrast to other inferior insulation material. The increased conductor heating through a permanent current load can be realised through silicone materials. Coroplast is capable of calculating the conductor heating depending on the operational environment temperatures and the current loads for an optimised dimensioning of the nominal conductor cross sections. So-called Derating-Simulations are used for selection of the optimal cross section. This results in the saving of costs, weight and construction room. By means of the current heating table shown below as an example, the maximum current load can be identified depending on the ambient temperature and the cable cross section. Further graphics for deviating ambient temperatures can be derived from our website at: Maximum current load per cross section according to the ambient temperature High voltage cable, single-core, shielded FLR2GCB2G, 25 mm² and 35 mm² High voltage cable, single-core, shielded HV-2GCB2G, 70 mm² ambient temperature +20 C +85 C +105 C +125 C nom. cross section max. current load up to conductor temperature of +180 C 10 mm² 154 A 121 A 108 A 92 A 16 mm² 206 A 162 A 144 A 123 A 20 mm² 232 A 182 A 163 A 139 A 25 mm² 274 A 216 A 192 A 164 A 30 mm² 300 A 236 A 210 A 180 A 35 mm² 343 A 270 A 241 A 206 A 40 mm² 378 A 298 A 266 A 227 A 50 mm² 432 A 340 A 304 A 260 A 70 mm² 538 A 425 A 380 A 325 A 2 3

3 Silicone-insulated multi-core high voltage automotive cables Application: HV aggregates and chargers Cable construction according to LV 216-2, ISO 6722, ISO Construction of HV wiring systems for hybrid and electric vehicles Multi-core, shielded automotive cables for high voltage cable sets Processing high voltage cables Multi-core, shielded high voltage sheathed cables are already being used today by different OEMs for the connection of HV aggregates. This includes, for example, air conditioning compressors, PTC auxiliary heaters and the vehicle-internal connection of the charging socket to the charger aggregate. Coroplast cables are characterised by their exceptional flexibility. The combination possibilities of the cables are greatly variable. A comprehensive construction table of the cables according to LV can be found at Furthermore, customer-specific constructions are possible. Through continuous development of HV cables, our customers place a high degree of importance on processibility. The latest generation of multi-core, shielded sheathed cables provide a filling layer on the core stranding for a circular construction. By doing so, the wire shielding can be separated with rotative cutting systems in a process secure manner without the danger of injuring the actual core insulation. Furthermore, the timeconsuming process of removing the filling elements and the separation can be avoided. All cables of the HV product family are characterised by a distinct roundness which makes processing easier. Latest technology Former technology High voltage cable, multi-core, shielded FLR2G2GCB2G round braided shielding on inner sheathing cutting buffer saving of one foil on the inside filler to remove manually no cutting buffer foil on the inside to remove manually braided shielding noncircular 4 5

4 PUR-sheathed cables for the charger connection Application: Charging of HV batteries of electric and hybrid vehicles Cable construction according to VDE 0282 Connection cables for 1-phase and 3-phase AC-charge Charging cables Charging cables in comparison Charging cables S05BQ-F The development is focusing on charging cables which connect an external voltage supply with the battery in the vehicle. The high requirements which must be fulfilled by charging cables have been identified in collaboration with German automobile manufacturers. Standard products which can be found on the market were compared in terms of the requirements profile and additionally supplemented and optimised by further technical requirements. Essentially the supplement of the current H07BQ-F cables takes place with special communication wires which secure the exchange of information between the external power supply and the vehicle. These so-called pilot conductors are identified with 0.5 mm² in Germany, e. g. with 0.75 mm² in France. Special VDE [Federation of Electro-technology Electronics Information Technology] approvals are available at Coroplast for these special constructions. In addition, the cables are set up in such a way that during transport they produce a low noise level in the car. The cable designs correspond to the conventional automotive requirements, highly flexible as well as mechanically extremely resilient, microbe resistant and media resistant. In combination with the tried-and-tested PUR-sheathed cables, the charging cables are intended for rough everyday use. Further information and comprehensive construction tables can be found under Coroplast PUR-sheathed cables offer the best sum of all characteristics for the use as charging cables. Alternatives, e.g. simple PVC cables according to state-of-the-art are only partially suitable for use in outdoor areas. The PUR-sheathed Coroplast cables do not shy away from the comparison with rubber sheathed cables. PUR is mechanically durable, features a higher UV resistance and can be processed further into coiled and spiralled charging cables very well. UL certified cables are implemented on the market overseas. These cables are insulated with specific TPE compounds which will not be used in Europe. Charging cables S07BQ-F Design table of a few selected charging cables Charging cables S05BQ-F including pilot core operating voltage U 0 /U max. 300/500 Volt number conductor core sheathing nom. resistance diameter diameter cross bare tinned section max. max. nom. tolerance nom. tolerance pilot core 0.50 mm Ohm/km 40.1 Ohm/km 1.75 mm ± 0.2 mm / / 3 x 1.5 mm Ohm/km 13.7 Ohm/km 3.1 mm ± 0.2 mm 9.3 mm ± 0.3 mm 5 x 6.0 mm Ohm/km 3.39 Ohm/km 5.0 mm ± 0.3 mm 17.1 mm ± 0.5 mm pilot core 0.75 mm Ohm/km 26.7 Ohm/km 2.0 mm ± 0.2 mm / / 5 x 4.0 mm Ohm/km 5.09 Ohm/km 4.6 mm ± 0.2 mm 15.9 mm 3 x 6.0 mm Ohm/km 3.39 Ohm/km 5.0 mm ± 0.3 mm 13.9 mm ± 0.4 mm Benchmark charging cables Rubber H07RN-F standard cables PVC H05VV-F TPU H07BQ-F TPU S07BQ-F special cables TPE EVE/EVJE halogen free coiled cables retraction force availability with pilot cores water proof overmoulding visualization sheathing defects UV resistance low volume and weight 6 7

5 Spiral cables, bend protection and strain relief Application: Charging of HV batteries of electric and hybrid vehicles Cable construction according to VDE 0282 Connection cables with improved handling Spiral cables Assembled charging cables with bend protection sleeves and strain relief We have implemented the requirement of OEM to create charging cables in a spiral construction. The use of coiled cables results in numerous advantages for the user. The cables cannot be dragged across the floor and thus do not get dirty. This is a strong argument for coiled charging cables on part of the user! Through the special constructional characteristics several 10,000 extension cycles can be presented without problems. Coiled charging cables prevent accidents. While straight cables represent tripping hazards, an expandable coiled cable prevents falls and can also be easily noticed by passers-by. Coroplast will gladly advise you on the optimal designs of the spiral leads according to your requirements. Beyond the straight cable and spiral lead, Coroplast also offers partially finished solutions. The know-how regarding the overmoulding of cables, which Coroplast has applied in the automobile industry for years, can be transferred to charging cables. Coroplast offers the possibility to enhance the product with an overmoulded protection grommet. The protective grommets are tailored to customer requirements and they offer reliable and effective strain relief as well as bend protection in the sensitive areas directly behind the socket or the device output. Charging cable, coiled Coil configuration WL AE 1 AE 2 WD 1 WD A NL Coil configuration in mm Length 1st connection end in mm Length 2nd connection end in mm Outer diameter of the coil in mm Inner diameter of the coil in mm Usable extended length in mm 8 9

6 PUR-sheathed cables for ebikes and pedelecs Nomenclature of HV cables and charging cables Application: To charge batteries Cable construction according to ISO 6722 and ISO Robust sheathed cables for the entire cabling of high-quality ebikes and pedelecs Special cables for ebikes Coroplast uses its experience in the production of sheathed cables for new applications in electric scooters, electric bicycles and pedelecs. The Coroplast cables can be constructed according to your individual wishes and they can take over the power transfer for the drive as well as the data transfer for the control. Furthermore, Coroplast provides the connection cables for charging the battery. Nomenclature HV cables Multi-core, double shielded sheathed cable (flexible) FLR2G2GCB2G 3x2.5/T180 Automotive cable Core insulation Thin wall acc. to ISO 6722 Core insulation made of mod. SIR FL R 2G 2G C B 2G 3 x 2.5 mm 2 / T 180 Filling sheathing made of mod. SIR Multi-core cables for ebikes operating voltages max. 60 Volt acc. to ISO st shield: braided wires 2nd shield: foil conductor core outer sheathing Outer sheathing made of mod. SIR number nominal cross section resistance max. outer diameter outer diameter max. tolerance max. tolerance Cable with 3 insulated cores Conductor cross section 2.5 mm² Working temperature acc. to ISO 6722 (3000 h +180 C) 4 x 4.6 mm sensor and data cables 0.35 mm² 53.7 Ohm/km 1.3 mm -0.1 mm 5 x 5.0 mm 2 x 4.3 mm 0.5 mm² 38.2 Ohm/km 1.6 mm -0.2 mm 3 x 4.8 mm -0.4 mm -0.4 mm Nomenclature for charging cables Multi-core cable (flexible) for voltages up to 500 Volt S05BQ-F 3G mm² S 05 B Q -F 3 G mm 2 4 x 7.5 mm Special cable power cables 1.5 mm² 13.2 Ohm/km 2.4 mm -0.2 mm 5 x 8.2 mm 2 x 8.3 mm 2.5 mm² 7.8 Ohm/km 3.0 mm -0.3 mm 3 x 8.6 mm -0.6 mm -0.6 mm Nominal voltage U 0 /U 300Volt/500 Volt Core insulation made of EPR Outer sheathing made of TPU-Polyurethane Conductor design fine wires 2 pairs 0.14 mm² 141 Ohm/km 1.2 mm -0.1 mm multifunctional cables 2 x 2.50 mm² 7.8 Ohm/km 3.0 mm -0.3 mm 2 pairs 0.35 mm² 53.7 Ohm/km 1.2 mm -0.1 mm 8.3 mm -0.6 mm 9.3 mm -0.6 mm Cable with 3 insulated cores with earth conductor with color green-yellow Conductor nom. cross section 2.5 mm² 2 x 2.50 mm² 7.8 Ohm/km 3.0 mm -0.3 mm Pilot core with conductor nom. cross section 0.5 mm² 10 11