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Production line for the damage-free processing of high voltage cables for electric and hybrid vehicles

Country of Origin: Germany
Reference Number: TODE20170202001
Publication Date: 10 February 2017

Summary

A German SME specialised in cable processing has developed a flexible production line for the damage-free processing of high voltage cables for electric and hybrid vehicles. Its modular setup allows the integration into existing production lines.The company looks for suppliers in the automotive industry for commercial agreements with technical assistance to integrate the technology. In addition to that partners to develop an automated solution are sought for technological cooperation agreements.

Description

High voltage coaxial cables are of high importance in the automotive industry. Electric and hybrid vehicles cause an even greater demand. High voltage cables must ensure the safe transmission of high voltage and the shielding of electromagnetic fields at the same time.  Before plugs or connectors are assembled, the cables must be processed. Up to now, 80-95% of processing steps are carried out manually, requiring a considerable amount of human workforce. That is why cable harnesses in electric automotive vehicles nowadays account for a relatively high percentage of the overall production costs. 

Conventional methods for the wire stripping cannot be applied anymore for certain cables. The cutting of shieldings by rotating blades, for instance, can lead to the damaging of underlying layers. For traction cables this is causing a problem since the underlying layer has an insulation function for the inner conductor. Even small damages of this layer can lead to severe voltage punctures. For other processing steps no mechanical solutions had been found yet.

The German SME developed a flexible production line consisting of individual docks, each carrying out specific processing steps. The docks are modular and can be assembled according to specific production needs. The individual manufacturing steps involve the dismantling of the outer sheaths, the removal of the insulation or shielding foil, the removal of the filling material/insulation and the stripping of the wire ends.

As for the cutting of shieldings of traction cables, a specifically designed machine for the damage-free cutting of shield braidings can be integrated into the production line to solve this problem. Other power cables can be cut by blades without causing problems, however unwanted wire rests can cause a problematic degree of contamination. A specifically designed cleaning device can be integrated in the production line to solve this problem.

The company looks especially for suppliers active in the automotive industry (especially cable confection for electric and hybrid vehicles) for commercial agreements with technical assistance to integrate the technology into their production systems. The necessary know-how for the technology-transfer will be supplied by the German SME.
Also partners to develop an automated solution are sought for technological cooperation agreements.

Advantages and Innovations

- Shortened manufacturing time 
- Cost savings
- Solutions take into account specific requirements for the processing of high voltage cables
- Flexible setup makes possible the combination with existing production lines and tailormade solutions
- High precision and standardised processes meet quality requirements for high voltage cables

Stage Of Development

Already on the market

Stage Of Development Comment

Parts of the production line are already on the market, others are still in the prototype phase

Requested partner

The company looks especially for suppliers active in the automotive industry (especially cable confection for electric and hybrid vehicles) to integrate the technology into their production systems for commercial agreements with technical assistance. Necessary know-how for the technology-transfer will be supplied by the German SME.

Also partners (research or industry) are sought for technical cooperation agreements to further develop the technology into an automated solution.

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