Products for e-mobility
with tomorrow in mind today

E-mobility

Our products for e-mobility offer you the right solutions for distributing, connecting, securing and switching high-voltage applications. Forschner’s product portfolio for passenger cars, light- and heavy-duty commercial vehicles includes power distribution units along with high-voltage cable sets.

 

 

Expertise and synergies

There is no question that e-mobility and electric vehicles involve especially young developments. With Forschner, you can rely on mature technologies and a broad company base. Synergies with the "Cabling Systems" and "Electromechanical Systems" divisions, well-established for many years now, enable targeted knowledge transfer within the Forschner Group - and that includes far-reaching capacity for serial production. As an expert supplier to the automotive industry, we haven’t earned ourselves a good reputation for nothing.

 

We know ...

... how we can support vehicle manufacturers with tailored solutions and profound expertise in e-mobility – one of the biggest paradigm shifts since the invention of the automobile.

 

HIGH-VOLTAGE DISTRIBUTION BOXES FOR E-MOBILITY

High-voltage distribution boxes for the most varied kinds of hybrid and electric vehicles: power distribution units from Forschner are the smart way to accompany the automotive future. We combine high-quality components into vehicle-specific overall solutions. For the power supply of the high-voltage components, instead of power rails, Forschner-patented round wire technology is used. It enables customized design in 2D and 3D –and this flexibility also helps to save space. The distribution boxes also function as stand-alone devices, integrated into a battery or flanged onto it. On request, we can also integrate electronic components such as DC/DC converters.

 

We know...

... how high-voltage distribution boxes best distribute, connect, save and switch.

The components

Circuit board technology

  • thick-film circuit boards
  • in all sizes and dimension

Innovative connection technology

  • Forschner-patented
  • for 3D contacting
  • saves space

HV switching elements

  • up to 1.000 V
  • up to 400 A

Sensor technology

  • current
  • voltage
  • temperature

 

HV connectors

  • Interlock System
  • Monitoring the contacting

Fuse protection

  • different voltage levels
  • automotive-tested

Cable glands

  • with screen connection

Casing

  • EMC shielding
  • space-optimized
  • including pressure equalizing valve

High-voltage wiring harnesses for E-Mobility

New drive concept meets solid expertise:High-voltage wiring harnesses from Forschner are based on decades of experience in the design and manufacture of low-voltage cable assemblies. Here, Forschner has already made a name for itself worldwide - for cars and especially trucks and buses, with amazing variety and minimal repetition rates.

 

We know ...

... how we can design high-voltage wiring harnesses with unique efficiency that is tailored to the vehicle.

High-end development

Even in the still-young e-mobility sector, Forschner has clear advantages – as a developer, manufacturer, logistics specialist and key solution supplier. In 2D wiring harness development, Forschner is intensively concerned with the selection of optimal plug connections. By means of smart connection technology – using material pairings and contact pressure - any contact resistances are minimized. With 3D wiring harness sets, minimal bending radii are also achieved, and all design rules regarding electromagnetic compatibility are taken into account.

Suitable accessories

Custom-made fastening concepts, from ducts, brackets and clamps to Interlock pin connector sockets developed by Forschner itself, round off the company’s offer in the high-voltage wiring harness sector. Forschner uses its own resources to take care of testing and qualification, minimizing interface losses and accelerating development and manufacturing processes.

 

E-Mobility - your advantages with Forschner

The voltages and currents that occur in hybrid vehicles and electric vehicles are much higher than in conventionally powered models. To safely control these, suitable solutions for power distribution are needed. Thanks to their broad range of options and functions, our high-voltage distribution boxes and wiring harnesses are just as impressive in passenger cars as they are in commercial vehicles.

 

We know ...

... what high safety requirements need to be met in the high-voltage sector.

High-end development according to customer specifications

Depending on the vehicle type, there are all kinds of different requirements in the area of e-mobility. With passenger vehicles it’s all about limited installation space and high-volume production, while with light trucks and buses the variety of variants is often especially pronounced. And in heavy commercial vehicles, particularly high currents and voltages occur. With a broad range of experience and real flexibility, we transform the most varied customer requirements into perfectly tailored solutions.

Technical cleanliness thanks to our own clean room

To ensure the highest level of technical cleanliness, assembly of the power distribution units and high-voltage wiring harnesses takes place in our clean room. Test chambers up to 30 m³ are available. Last but not least: electric, pneumatic and hydraulic test benches and systems for digital microscopy. Simulation and validation are also implemented in-house – and that also goes for high-voltage wiring harnesses. Efficient processes, plus a strong team at three locations with currently around 50 developers in the "E-Mobility" division, create good conditions for rapid prototyping. Forschner is also well-positioned in terms of machinery – it has its own 3D printer, for instance, which makes time-consuming and costly injection molding processes unnecessary in this phase.

Safety on board

100 percent pre-assemblable, mechanically and optically codable, vibration-resistant, resistant to electricity, and fireproof. With our Power Distribution Units and high-voltage wiring harnesses, we offer solutions that guarantee a safe high-voltage connection in modern electric and hybrid vehicles, from SUVs to trucks. Compared with competing products, our e-mobility solutions feature lower thermal distortion as well as material savings at the same time. The combination of press-in and crimping technology on a PCB basis results in unrivaled quality and process reliability.

Innovative details

With our patented connection technology in the form of round wires, we enable direct connections - even diagonally. Compared to conventional power rails, customized design in 2D and 3D enables significant installation-space savings. Our Interlock pin connector sockets that we developed ourselves are a further example of how we’re advancing the mobility of the future with creative ideas.

Intensive quality assurance

  • Thermal shock testing
  • System simulations
  • Heating and cooling tests in vehicle position
  • Vibration tests
  • Test for tightness up to 200 bar
  • Test for climate and temperature resistance -70°C to 300°C (98% )
  • Test for vibration resistance
  • Current measurement up to 800 A
  • Voltage measurement up to 1000 V

We shorten and optimise development processes

Take advantage of our FOR-tech development support—we shorten development times and cut production and manufacturing costs thanks to unique proven know-how. At the same time we keep an eye on the overall process right from the start and support you on site with our resident engineers. See here to find out more.

 

Your contact person

 

Mr Neumann

E-Mail: neumann@forschner.com