Rosenberger has developed the HVR range of high-voltage connectors especially for power transmission in electric and hybrid vehicles. The connecting system consists of connectors for current loads up to 40 A (HVR 40) and 200 A (HVR 200) in various cable diameters, flat-contact connectors, direct-contact connectors as well as power distribution units for the arrangement of customer assembly formations. The connectors’ ’high-voltage interlock loop’ (HVIL) prevents unintentional connection/disconnection when under current load.
HVR direct-contact connectors are used in applications such as connecting cables to adaptor systems, to batteries or for other connection applications in the engine compartment. The connector system consists of direct-connectors with cable cross-sections from 2,5 up to 95 mm²; such direct-contact connections cannot be disconnected later. The system features high current carrying capacity in tight spaces and is waterproof according to IP X6K9K thanks to a 3-lip gasket. EMI shielding is provided by a 360 braid.
For installation of HVR 40 and 200 contact and connecting systems, Rosenberger provides so-called PDUs – power distribution units – which can be adapted to customer-specific requirements. They are EMI shielded and waterproof according to IP X6K9KA. Using copper bus bars assemblies can be arranged according to customer-specific and space-saving needs.
The connection technology established in PDUs can also be applied for other high-voltage applications, eg, power bridges for connecting batteries, connecting engine to battery, or connections to other interfaces.
The Rosenberger flat-contact connector system is mainly used for power transmission in the tightest spaces. The flexible current bar system permits customer-specific designs, with a maximum current load of 250 A. Thanks to the so-called ‘contact sword’ (2 x 14,5 mm) the easy-to-mount and vibration-resistant flat-contact connectors are mateable with other commercially available flat-contact devices on the market.
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