EuroWire September 2024

Technology News

Mastering busbar insulation Modern electric vehicles (EVs) are equipped with high-voltage components that require a stable and efficient power supply. For busbars to perform their function safely over the entire service life, high-quality insulation is necessary. In July 2011, Rosendahl commissioned the first busbar insula tion line. Since then, with the rise of e-mobility, these high-per formance “flat cables” have gained significant importance. They have become an integral part of EVs, facilitating the conduction and distribution of power within electrical systems. The main advantage of busbars is their ability to handle higher currents than traditional cables, resulting in a reduction of power loss. Their distinctive flat shape is optimised for efficient use of the space available within a vehicle’s electrical construction. Busbars are more challenging to process than traditional cables with round cross-sections. Even minor deviations can noticeably impact wall thickness distribution, so precise control from payoff to take-up is required for maintaining quality. Every line component must be precisely calibrated to achieve seamless production.

These measures ensure a high level of adhesion between the aluminium or copper conductor and the insulation layer – a primary quality factor for the final product. Rosendahl Nextrom https://rosendahlnextrom.com

High-performance CAN-Bus cable for advanced engine control systems

German cable engineering firm Hradil has introduced a shielded high-performance CAN-Bus cable for the engine and exhaust control systems of heavy-duty 12-cylinder diesel engines. Hradil’s CAN-Bus cable fulfils the demanding requirements set out in the Society of Automotive Engineers’ SAE 1939-11, SAE J1939-14 and SAE J1128 standards, and is one of only a small number of cables capable of meeting the criteria. The cable is suitable for dynamic applications such as drag chains, and is used for cranes, excavators, construction machinery and agricultural vehicles, in environments such as mining, tunnel construction, oil drilling rigs or the chemical industry. Owing to its special design, the cable can be relied on to resist high mechanical stresses and extreme temperatures ranging from -40 to +125°C. Hradil’s engineers developed the new high-performance CAN Bus cable for the purpose of managing heavy-duty diesel engines where fast data transmission and high transfer rates are essential. With specific impedance characteristics at 120 ohms, the Hradil CAN-Bus is claimed to ensure optimal transmission rates with minimal signal reflection and losses. The cable supports the transmission of sensor and diagnostic data as well as control data, such as engine rpm and temperature data as required by the parameter list defined in SAE J1939. The Hradil CAN-Bus cable is compliant with standards SAE J1939-11 (which defines the physical layer for high-speed CAN); SAE J1939-14 (the physical layer for 500 kbps applications); and SAE J1128 (the requirements of low-voltage primary cables of 60 VDC (25 VAC) or lower in surface vehicle electrical systems). In addition to its electrical characteristics, the cable has high resistance against oil, petrol, most alkaline and acidic media, and coolants and lubricants. As the cable was designed for outdoor use, it is resistant to ozone and UV radiation. Self extinguishing and flame-retardant properties make it compliant with the fire protection standards IEC 60332-1-2 and UL94-VO.

Rosendahl’s busbar insula tion solution pays special attention to the conductor cleaning process before ex trusion, and proper cooling afterwards.

Busbars have become an integral part of electric vehicles

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The cable jacket is produced from a special compound that results in robustness and durability. Hradil Spezialkabel GmbH www.hradil.de

High-performance CAN-Bus cable

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September 2024