HITACHI Power Harness For Hybrid Electric Vehicle

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HITACHIPower Harness For Hybrid Electric
Vehicle
Hitachi Cable Ltd. Industrial System
Department April 2001
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CONTENTS(1)

• 1. Corporate Profile
• 1.1 Company Outline
• 1.2 Sales
• 1.3 Sales for Automotive Industry
• 1.4 A Brief History of Automotive Business
• 1.5 Major Customers
• 2. Worldwide Facilities
• 2.1 Japan
• 2.2 International
• 3. Condition of use
• 4. Selection of cable
• 4.1 The Point of selection
• 4.2 The basis of data
• 4.3 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 sec
• 4.6 700A heat rise for 20 sec
• 4.7 Conclusion
• 4.8 Ampacity

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CONTENTS(2)

• 4.10 Arc Experiment results
• 4.11 EMI Simulation results
• 4.12 Benefits of HEV cable
• 5. 3 pole connector cable concept
• 6. Coaxial battery cable concept
• 6.1 Coaxial battery cable connector concept
• 7. Brake-By-Wire
• 7.1 Advantages of Hitachi BBW Cable and
  connector
• 7.2 Connector concept
• 7.3 Cable types

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1.1 Company Outline
1. Corporate Profile

• Establishment 1956
• Capital 26 billion yen
• Sales 320 billion yen
• Employees 6600
• Primary Products Wire Cable Copper Products
• 
  Electronic Material Components
  
  and Rubber Products
• Sales Office Tokyo Head-office and
  14 branch offices
• Products Facilities Six in Ibaraki and one in
  Aomori

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1.2 Sales (1998)
Automotive
Telecommunication Cables
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5
Export
Power Cables
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Domestic others
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Electric Machine Industry
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Total Sales Approx.30billion yen/Month
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Construction Industry
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1.3 Sales for Automotive
Brake PAS Hose Assembly
AV Wire Cable
Magnet Wire Clad Materials
Copper Strip Fin Tube
ABS (Sensor Cable)
FFC (Flexible Flat Cable)
Others
Approx. 2 Billion yen/month W/W
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1.4 A Brief Record for Automotive Business(1)
1969 Awarded Nissan Brake Hose Business. 1971
Started Production of Automotive Wire
Cable. 1973 Founded Kyohritsu Hiparts
Ltd. Awarded Mazda Brake Hose Business. 1975
Awarded Isuzu Brake Hose Business. 1980
Awarded GM(OPEL) Brake Hose Business. 1987
Awarded Ford Brake Hose Business.
Established Hose Assembly
Production in The USA(HCI). 1991
Awarded Toyota Brake Hose Business.
Started Production of ABS Cable.
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1.4 A Brief Record for Automotive Business(2)

• 1992 Awarded Honda Brake Hose Business.
• 1994 Established Hose Assembly Company in
  Mexico(HCQ)
• 1997 Started Production of Halogen-Free-Cable.
  
• 1998 Started Production of JAMCAT.
• Started Production of ABS Sensor.
• 1999 Established Hose Assembly Cable
  Production in
• Philippines(HCP)
• Started Assembly of Brake Hose for
  Motorcycles.
• 2000 Established Hose Assembly in
  Europe(HCUK).
• Started Production of HEV Cable of
  TOYOTA PRIUS.

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1.5 Major Customers

• Vehicle Manufacturers
• FORD HONDA ISUZU MAZDA NISSAN
  OPEL ROVER SAAB SUBARU TOYOTA
• VAUXALL etc.
• Automotive Components Manufacturers
• ASMO ALPS ELECTRONIC DENSO HITACHI
• JIDECO KOYO SEIKO KYOURITSU HIPARTS
• MITSUBA SHOWA TOKICO UNISIA JECS
• ZEXEL etc.

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2.1 Japan
2. Production Facilities
Densen Works
Hitaka Works
LocationHitachi Rubber Hose ABS Sensor
LocationHitachi Wire Cables AV Wires JAMCAT
Toyoura Works
Tsuchiura Works
LocationTsuchiura Commutating Materials Copper
Products for Heater Copper Foils
LocationHitachi Magnet Wires for Motor Clad
Materials FFC
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2.2 International
HCUK
HCI
HCL
HCP
HCQ
International Operation HCI Hitachi
Cable Indiana HCQ Hitachi Cable
Queretaro HCL Hitachi Cable Limited
HCP Hitachi Cable Philippines HCUK
Hitachi Cable UK
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3. Condition of use

• Voltage 42V
• Current (Peak) 500A-60sec.
• Current (Normal) 175A(RMS)
• Environment Temperature Max 120 C

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4. 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.

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Table 1. Rise temperature of normal current
Table 2. Rise temperature of short time current
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4.3 The rise in conductor temperature(Normal
current 175A)
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4.4 The rise in conductor temperature(Peak
current 500A)
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4.5 550A Peak for 3sec.
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4.6 700A peak for 20sec.
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• 4.7 Conclusion
• Conductor size 40mm2
• Material of insulation Fluonlex
• Specification of cable

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4.8 Ampacity
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4.9 Insulation material option
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4.10 ARC Experiment Results
Rate400mm/min With insulation on Pin contact tip
Rate400mm/min Without insulation on Pin contact
tip
Voltage 48V Current 30A
Rate50mm/min With insulation on Pin contact tip
Rate50mm/min Without insulation on Pin contact
tip
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4.11 Measurement by Magnetic close sensor
Principle
Appearance
CONNECTOR
CABLE
Magnetic field
Shield Box (Iron)
Table
Circuit
Coil
Spectrum Analyzer
Frequency1MHz
(2)Without Shield Case
(1)With Shield Case
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4.12 Benefits of Hitachi Cables 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.

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5. 3 Pole connector cable concept
Cable Specification
Cross section
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6. Coaxial battery cable concept
Cable specification
Cross section
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6.1 Coaxial cable connector concept
Cable specification
Cross section
Connector Concept Coaxial Development item 1.
Insert Mold Insert molding is difficult regarding
Pin-Contact two Ring spacers and especially
Socket Contact. 2. Mating Force Mating force of
the connector is expected to be large due to a
large number of contact points. 3. Contact Method
of Shield Wire to The Case It is not decided how
to contact shield wire(external side) to the
case. It is necessary to find a good method. 4.
Temperature Rise Temperature is expected to
largely increase because of big current with dual
structure. It is necessary to select a proper
material.
Cross section
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7.0 Brake-By-Wire Cable and Connector
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7.1 Brake-By-Wire Cable and Connector

• Advantages
• Cable
• 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

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7.2 BBW Connector Concept
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7.3 Brake-By-Wire Cable currently under
development
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