Connectors & Adaptors

The Rosenberger HPK system can achieve 275 A at 85 °C up to 1000 V. With their excellent vibration and current capacity performance the HPK connectors are well-suited to typical high-voltage electric vehicle applications such as the connection between battery, inverter and PDU. The range includes 1-, 2-, or 3-pole connectors which for maximum flexibility can be used with copper or aluminum cables in four different cable cross sections. Straight and angled cable couplers as well as corresponding headers are available, either with or without HVIL (high-voltage interlock).

Complementing its standard HV connector portfolio, Rosenberger develops and manufactures customer-specific high-voltage components for electric and hybrid vehicles. These enable the lowest possible transition resistances, ensuring long-term low-loss performance and reliability in critical electrical systems such as those for battery charging, cell management, heating, and air conditioning. From concept to final delivery, Rosenberger high voltage custom components are the perfect fit every time. Using its component toolkit, including PDUs, Y-splitters, Busbars and Cell Modules, Rosenberger can develop and manufacture a wide array of tailor-made solutions. These are designed and configured precisely to the relevant vehicle architecture, allowing ideal combinations of the various fuses, relays and other passive and active components required. Power Distribution Units (PDU) Power distribution units (PDU) for vehicles have multiple power input and outputs and use all kinds of connectors, fuses, and relays. In these cases, the PDU generally forms the central link between the vehicle power electronics and batteries, electric motors, and other ancillary units. Y-Splitters Y-splitters are used to distribute the power from one cable harness to two or more units, e.g., between a DC/DC converter and an electric air-conditioning unit. Rosenberger can design Y-splitters for applications with and without shielding for cable cross sections from 4 mm² to 95 mm² in collaboration with the customer. Cell Module Connectors The Rosenberger HV portfolio also includes cell module connectors. These connectors are required to link battery modules within a battery pack. For typical battery applications, multiple custom-designed battery connection points are required. Based on the robust pressure contact system, Rosenberger offers cell module connectors without flexing parts in the contact area. Systems from 100 to 350 A are available. Different assembly directions, coding variants as well as cross sections can be implemented according to customer-specific requirements.

With its high capacity, compact design the Rosenberger DCS is perfect for space-confined high voltage applications where direct connection is a prerequisite. With a cable cross-section of just 70 mm² the current carrying capacity is 340 A at 85 °C, making it ideal for battery charging or enabling direct connection between the battery and motor components used in electric vehicles.

Rosenberger HV fuses ensure the safety of high voltage PDUs used in electric vehicles. Watertight and vibration-proof, they feature a HVIL (high-voltage interlock) and are characterized by their lightweight plastic housing. Fuses and the corresponding insert can easily be replaced without opening the component housing.

Rosenberger’s High-Voltage Test & Measurement Solutions deliver deep insights into the EMC behaviors of high-voltage Automotive Traction Networks. Using our powerful HV measurement coupler, dedicated calibration software and calibration kits, EMC experts can perform RF voltage and current reliability calculations with absolute precision. HPK Measurement Coupler The newly developed HV Measurement Coupler for HPK series from Rosenberger enables a minimally invasive testing method for measuring the reliability of RF voltages and currents. In conjunction with a dedicated calibration process, patented algorithms accurately calculate the RF currents and voltages in the calibration reference plane. Furthermore, due to the minimal invasion techniques deployed by the coupler there is no risk of impairment to harness performance when under test. The watertight and robust design also means testing can be carried out under any environmental conditions. HPK Calibration Kit Although the HPK measurement coupler includes calibration data, an optional HPK calibration kit is also available. Combined with the RCTD software it enables customers to manage their own calibration requirements themselves. A set of all necessary calibration standards is provided and a description for the acquisition of calibration files is included in the RCTD user manual. Rosenberger recommends 12-monthly calibration intervals and offers a recalibration service to HPK coupler customers if required. RCTD Software Rosenberger Calibrated Time Domain Software (RCTD) was developed to enhance EMC-related, automotive high-voltage measurement capabilities. Within the RCTD Software, the time domain data captured by an oscilloscope using the high-voltage coupler is post-processed to calculate high frequency currents and voltages at the given calibration plane within the high-voltage power train. Therefore, calibration data is created and taken into account before measurement occurs. Delivered on a USB-stick in a sturdy wooden box, the RCTD Software includes the functions to create calibration data and post process the measurement data on a PC or directly on LeCroy HDO oscilloscopes for real-time evaluation. The software can be also used for any other directional coupler.

Rosenberger HVR®50 connectors are available in straight and angled variants. The additional slide locking mechanism (CPA – Connector Position Assurance) prevents accidental disconnection. Despite their small size these connectors achieve a current capacity of approximately 60 A at 85 °C. HVR®50 connectors are mainly used in ancillary units such as electrical heating systems, air-conditioning units, DC/DC converters, and for charging batteries.

Rosenberger HVR®200 connectors offer an excellent dimension/performance ratio, combining high current carrying capacity of 210 A at 85 °C while keeping dimensions to a minimum. These two-pin connectors are ideal for connecting elements between a battery and an inverter or for installation in power distribution units (PDU). To suit the relevant installation or usage requirements, the portfolio includes an angled or straight header as well as a straight cable coupler.

The 3-pole HVR®260 connector system for collective shield applications is used to connect electric motors up to a continuous current of 270 A. Despite its lightweight aluminum housing it is capable of operating safely at extreme temperature ranges from -40 °C to +150 °C. It is certified to vibration severity level IV. Customer-specific variants are available on request.

The Rosenberger HVR®300 connector system not only provides a maximum current carrying capacity of 320 A, it takes up minimal space. It features a 2-pole angled coupler for shielded cables and a cable cross section of 70 mm² along with the corresponding header. A cross section of 50 mm² is available on request. The lever locking mechanism is secured with an additional slider (CPA – Connector Position Assurance) to prevent accidental unmating.