Y-splitter connects high-voltage auxiliary units in electric vehicles

September 10, 2015 // By Christoph Hammerschmidt
Cable harness provider Leoni AG has is addressing wiring issues in hybrid and electric vehicles: The company has developed a lightweight yet robust Y-splitter that provides a safe and low-resistance connection of auxiliary units in high-voltage units. The product helps to simplify wiring design for these vehicles, the company claims.

The new Y-splitter securely and in a space-saving way splits the power between two high-voltage units, as is becoming ever more necessary in HV architectures. For example, it will split the power between the air conditioning compressor and the electric heater. The component is currently set up for 800 volts.

High-voltage wiring systems use shielded cables to ensure their electromagnetic compatibility (EMC) and, in the event of a fault, to conduct the short circuit current until it triggers the melting fuse. Due to the full harness integration, the Y-splitter does away with fault-prone connectors and thereby establishes a more reliable and safe enables connection for the load carrying cables . It also registers lower resistance of less than 6 milliohm at the contact transition from the 360-degree braided shield of the cable to the splitter’s housing. Thanks to the mechanical decoupling, the all-round contact furthermore gives the cable strain relief across the jacket.

The multilayered hybrid housing, made of metal and plastic, meets the relevant EMC requirements and provides protection against environmental influences . An additional potential equalisation as well as monitoring by means of a high-voltage interlock loop (HVIL) are not required, effectively reducing weight and size of the splitter in comparison to existing solutions.

The product is designed for twin-core, high-voltage silicone cables with a conductor cross section of 2 x 6 mm². Thanks to the splitter’s simple construction, it can be scaled to other wire sizes. 

More information: www.leoni.com