hitachi power harness for hybrid
TRANSCRIPT
HITACHIHITACHIPower Harness For Power Harness For
Hybrid Electric Vehicle Hybrid Electric Vehicle
Hitachi Cable, Ltd.
Industrial System DepartmentApril, 2001
CONTENTS(1)CONTENTS(1)1. Corporate Profile1. Corporate Profile
1.1 Company Outline1.2 Sales 1.3 Sales for Automotive Industry1.4 A Brief History of Automotive Business1.5 Major Customers
2. Worldwide Facilities 2. Worldwide Facilities 2.1 Japan 2.2 International
3. Condition of use3. Condition of use4. Selection of cable4. Selection of cable
4.1 The Point of selection 4.2 The basis of data4.3 The rise in conductor temperature(Normal current : 175A) 4.4 The rise in conductor temperature(Peak current : 500A) 4.5 550A heat rise for 3 sec4.6 700A heat rise for 20 sec4.7 Conclusion4.8 Ampacity4.9 Insulation options
CONTENTS(2)CONTENTS(2)
4.10 Arc Experiment results4.11 EMI Simulation results4.12 Benefits of HEV cable
5. 3 pole connector cable concept6. Coaxial battery cable concept
6.1 Coaxial battery cable connector concept
7. Brake-By-Wire 7.1 Advantages of Hitachi BBW Cable and connector7.2 Connector concept7.3 Cable types
1.1 Company Outline 1.1 Company Outline
EstablishmentEstablishment 19561956 Capital Capital 26 billion yen26 billion yen Sales Sales 320 billion yen320 billion yen Employees Employees 66006600 Primary ProductsPrimary Products Wire & Cable, Copper Products,Wire & Cable, Copper Products, Electronic Material, Components, Electronic Material, Components,
and Rubber Products and Rubber Products Sales Office Sales Office Tokyo Head-office, and 14 Tokyo Head-office, and 14
branch officesbranch offices Products Facilities Products Facilities Six in Ibaraki, and one in AomoriSix in Ibaraki, and one in Aomori
1. Corporate Profile
Total SalesApprox.30billion yen/Month
1.2 Sales (1998)1.2 Sales (1998)
Power Cables
Construction Industry
Automotive
Telecommunication Cables
14%
5%
Electric & Machine Industry
24%
4%
15%
Domestic others
17%
Export
21%
Approx. 2 Billion yen/month W/W
1.3 Sales for Automotive 1.3 Sales for Automotive
58%
18%
12%
6% 2% 2% 2%
Brake & PAS Hose Assembly
AV Wire & Cable
Magnet Wire, Clad Materials
Copper Strip, Fin, Tube
ABS (Sensor & Cable)
FFC (Flexible Flat Cable)
Others
1969 Awarded Nissan Brake Hose Business.1969 Awarded Nissan Brake Hose Business.1971 Started Production of Automotive Wire & Cable.1971 Started Production of Automotive Wire & Cable.1973 Founded “Kyohritsu Hiparts Ltd.”1973 Founded “Kyohritsu Hiparts Ltd.”
Awarded Mazda Brake Hose Business.Awarded Mazda Brake Hose Business.1975 Awarded Isuzu Brake Hose Business.1975 Awarded Isuzu Brake Hose Business.1980 Awarded GM(OPEL) Brake Hose Business.1980 Awarded GM(OPEL) Brake Hose Business.1987 Awarded Ford Brake Hose Business.1987 Awarded Ford Brake Hose Business.
Established Hose & Assembly Production Established Hose & Assembly Production in The in The
USA(HCI).USA(HCI).1991 Awarded Toyota Brake Hose Business. Started Production of ABS Cable.
1.4 A Brief Record for Automotive Business(1)1.4 A Brief Record for Automotive Business(1)
1992 Awarded Honda Brake Hose Business.1992 Awarded Honda Brake Hose Business.1994 Established Hose Assembly Company in Mexico(HCQ) 1994 Established Hose Assembly Company in Mexico(HCQ) 1997 Started Production of Halogen-Free-Cable.1997 Started Production of Halogen-Free-Cable.1998 Started Production of “JAMCAT”.1998 Started Production of “JAMCAT”. Started Production of ABS Sensor.Started Production of ABS Sensor.1999 Established Hose Assembly & Cable Production in 1999 Established Hose Assembly & Cable Production in Philippines(HCP)Philippines(HCP) Started Assembly of Brake Hose for Motorcycles.Started Assembly of Brake Hose for Motorcycles.20002000 Established Established Hose Assembly in Europe(HCUK). Hose Assembly in Europe(HCUK). Started Production of HEV Cable of TOYOTA PRIUS.Started Production of HEV Cable of TOYOTA PRIUS.
1.4 A Brief Record for Automotive 1.4 A Brief Record for Automotive Business(2)Business(2)
Vehicle Manufacturers FORD, HONDA, ISUZU, MAZDA, NISSAN, FORD, HONDA, ISUZU, MAZDA, NISSAN,
OPEL, ROVER, SAAB, SUBARU, TOYOTA, OPEL, ROVER, SAAB, SUBARU, TOYOTA,
VAUXALL etc.VAUXALL etc.
Automotive Components Manufacturers ASMO, ALPS ELECTRONIC, DENSO, HITACHI,ASMO, ALPS ELECTRONIC, DENSO, HITACHI,
JIDECO, KOYO SEIKO ,KYOURITSU HIPARTS,JIDECO, KOYO SEIKO ,KYOURITSU HIPARTS,
MITSUBA, SHOWA, TOKICO, UNISIA JECS, MITSUBA, SHOWA, TOKICO, UNISIA JECS,
ZEXEL, etc.ZEXEL, etc.
1.5 Major Customers1.5 Major Customers
2.1 Japan2.1 JapanDensen Works Hitaka Works
Toyoura Works Tsuchiura Works
Location:Hitachi
Rubber Hose
ABS Sensor
Location:Hitachi
Magnet Wires for Motor
Clad Materials
FFC
Location:Hitachi
Wire & Cables
AV Wires
JAMCAT®
Location:Tsuchiura
Commutating Materials
Copper Products for Heater
Copper Foils
2. Production Facilities
HCI
HCP HCQ
HCL
2.2 International2.2 International
International Operation
HCI : Hitachi Cable Indiana
HCQ : Hitachi Cable Queretaro
HCL : Hitachi Cable Limited
HCP : Hitachi Cable Philippines
HCUK : Hitachi Cable UK
HCUK
3. Condition of use3. Condition of useVoltage : 42V
Current (Peak) : 500A-60sec.
Current (Normal) : 175A(RMS)
Environment Temperature : Max 120 C
4. Selection of cable4. Selection of cable
4.1 The point of selection Temperature of conductor at normal current
Temperature of conductor at peak current
4.2 The basis of data We have already developed the 8mm2 cable, the experimental results vs
the calculate results for temperature rise of the conductor are displayed in the following table.
We have confirmed that the experimental results are lower than the calculated results.
On the basis of this confirmation, conductor size was decided by calculation.
Time(sec.)Current Description
60 120 180
Experiment 14.2 23.7 32.1100 A
Calculation 15.9 29.0 39.7
Experiment 19.8 34.8 45.2120 A
Calculation 22.9 41.7 57.2
Experiment 32.8 56.5 74.9150 A
Calculation 35.8 65.2 89.4
Rise temperature (deg C) Current
Experiment Calculation 30 A 7.3 8.1 50 A 17.5 22.5 65 A 28.7 38.0
Table 1. Rise temperature of normal current
Table 2. Rise temperature of short time current
4.3 The rise in conductor temperature(Normal current : 175A)
0
10
20
30
40
50
60
70
80
90
100
0 600 1200 1800 2400 3000 3600Time(sec.)
Ris
e te
mpe
ratu
re (
deg
C)
20 mm230 mm240 mm250 mm2
4.4 The rise in conductor temperature(Peak current : 500A)
0
50
100
150
200
0 30 60 90 120 150 180Time(sec.)
Ris
e te
mp
erat
ure
(deg
C)
20 mm230 mm240 mm250 mm2
4.5 550A Peak for 3sec. 4.5 550A Peak for 3sec.
0
5
10
15
20
0 1 2 3 4 5 6 7 8 9 10Time(sec.)
Ris
e te
mp
erat
ure
( )
30 mm2
40 mm2
4.6 700A peak for 20sec.4.6 700A peak for 20sec.
0
5
10
15
20
25
30
0 5 10 15 20 25 30Time(sec.)
Ris
e te
mpe
ratu
re(
)
30 mm2
40 mm2
50 mm2
4.7 Conclusion4.7 ConclusionConductor size : 40mm2
Material of insulation : Fluonlex®
Specification of cableSpecification of cable
Item Unit Standard Value
No. of core - 1Section area mm2 40Construction No./mm 19/26/0.32ConductorDiameter(Approx.) mm 9.5Thickness mm 1.4
InsulationDiameter mm 12.4Construction End/Carrier/mm 8/24/0.18Shield
Braid Thickness mm 0.45Sheath thickness mm 1.6Overall diameter(Appox.) mm 16.5Conductor resistance(20) Ohm/km 0.48
Conductor
Insulation (Fluonlex)
Braid shield
Sheath(PVC)
4.8 Ampacity 4.8 Ampacity
0
100
200
300
0 50 100 150Temperature(C)
Am
paci
ty(A
)
XLPE 30sq
XLPE 40sq
FLOUNLEX 30sq
FLOUNLEX 40sq
4.9 Insulation material option4.9 Insulation material option
Item XLPE FLOUNLEX Maximum
Temperature 120°C 150°C
Flexibility X XX Oil resistance XX XXX Heat resistance XX XXX Ampacity of 40mm2
cable at 80? 140A (100)
177A (126)
Cost XXX XX
XXX - Excellent XX - Good X - Fair
4.10 ARC Experiment Results4.10 ARC Experiment ResultsRate : 400mm/min
With insulation on Pin contact tipRate : 400mm/min
Without insulation on Pin contact tip
Voltage : 48VCurrent : 30A
Rate : 50mm/minWith insulation on Pin contact tip
Rate : 50mm/minWithout insulation on Pin contact tip
4.11 Measurement by Magnetic close sensor4.11 Measurement by Magnetic close sensor
Frequency: 1MHz
( 1 ) With Shield Case
SpectrumAnalyzerShield Box
( Iron )
Table
50Ω
CONNECTOR CABLE
Magnetic field
Coil
PrincipleAppearance
Circuit
( 2 ) Without Shield Case
SpectrumAnalyzer
4.12 Benefits of Hitachi Cable’s HEV Cable4.12 Benefits of Hitachi Cable’s HEV Cable
Arc Suppression during Connection and Disconnection if safety interlock is incorporated.
Capable of carrying high currents, yet protected from the harsh automotive environment.
Connector can rotate without twisting of cable on single pole version.
Connector is designed to utilize shielded or unshielded cable.
Oxygen Free Copper (OFC) is used in the wire. Cross connection protection by utilizing multiple key
configurations.
5. 3 Pole connector cable concept5. 3 Pole connector cable conceptCable Specification
---- 1
Cross section area mm2 40
Construction No./mm 19/26/0.32TA
Diameter mm 9.5
Thickness mm 1.4
Diameter mm 12.3
mm 26.8
ShieldBraid
Thickness mm 0.45
mm 1.6
mm 30.9
Ω/km 1.42
Kg/km 1,800
Item Unit Specification Value
No. of core
Conductor
Insulation
Cabling diameter
Construction
Conductor resistance (20°C)Estimate weight
No./No./mm 15/24/0.18TA
Sheath thickness
Overall diameter (Approx.)
Cross section
6. Coaxial battery cable concept6. Coaxial battery cable concept Item Unit Specification value
No. of core ? 1 Cross section area mm2 40 Construction No./mm 19/26/0.32TA Conductor Diameter mm 9.50 Thickness mm 1.10
Insulation Diameter mm 11.7 Construction No./No./mm 26/19/0.32TA Wrapping
Shield Thickness mm 1.60 Sheath thickness mm 1.60 Overall diameter (Aprox.) mm 18.10 Conductor resistance (20°C) Ω/km 1.39 Estimate weight kg/km 980
Inner conductor
InsulationOuter wrapping conductor
Sheath
Cross section
Cable specification
6.1 Coaxial cable & connector concept6.1 Coaxial cable & connector concept Item Unit Specification value
No. of core - 1Cross section area mm2 40Construction No./mm 19/26/0.32TAConductorDiameter mm 9.50Thickness mm 1.10
InsulationDiameter mm 11.7Construction No./No./mm 26/19/0.32TAWrapping
Shield Thickness mm 1.60Sheath thickness mm 1.60Overall diameter (Aprox.) mm 18.10Conductor resistance (20) Ω/km 1.39Estimate weight kg/km 980
Inner conductor
InsulationOuter wrapping conductor
Sheath
Cross section
Cable specification
Connector Concept: CoaxialDevelopment item1. Insert MoldInsert molding is difficult regarding Pin-Contact, two Ring spacers, and especially Socket Contact.2. Mating ForceMating force of the connector is expected to be largedue to a large number of contact points.3. Contact Method of Shield Wire to The CaseIt is not decided how to contact shield wire(external side)to the case. It is necessary to find a good method.4. Temperature RiseTemperature is expected to largely increase because of big current with dual structure. It is necessary to select a proper material.
Cross section
7.0 Brake-By-Wire Cable and 7.0 Brake-By-Wire Cable and ConnectorConnector
7.1 Brake-By-Wire Cable and 7.1 Brake-By-Wire Cable and ConnectorConnector
AdvantagesCable
• Same diameter as current brake hose• High bending characteristics by combining
brake hose and cable technologies.• Power lines and Shielded Signal lines
combined in one cable
Connector• High Reliability• Waterproof• Integral strain relief
7.2 BBW Connector Concept7.2 BBW Connector Concept
7.3 Brake-By-Wire Cable currently 7.3 Brake-By-Wire Cable currently under developmentunder development
Item Type A Type B Type CNo. 1 2 3 4 5
Construction 5x0.2mm2+2x2mm2 2x0.2mm2+2x2mm2 3Px0.2mm2+2x2mm2 4x0.5mm2 4Px0.2mm2
Shield Braid (mm) 0.12 0.1 0.1 0.12 0.08Material Insulation SheathMax overall diameter (mm) 8.6 9.0 10.5 7.2 10.3Characteristics
High voltage use (MAX:350V)
Specification of BBW Cable
Power lines and shielded Signal lines in one cable
42V use
Power line and Signal line in separate cables
Type D
Uniflammable Cross linked PolyurethanePolyurethane