The modules installed in the high-voltage battery must be electrically contacted with each other. Currently, screw connections with busbars made of copper material are predominantly used for this. It is also possible to use plug connections with flexible cables or busbars.

Advantages of plug connections

Compared with screwed and rigid busbars, plug connections with flexible cables offer a number of advantages:

  • Easy assembly: Only the plug and counterpart have to be connected. This also facilitates the disassembly of the modules in the battery pack during later servicing, for a second life or for battery recycling. The flexible cables can also compensate positioning tolerances in the battery modules of several millimeters.
  • Safety: Normed, touch-protected contact parts mean that no danger is presented by exposed electrical high-volt contacts.
  • Robustness in practice: If there are strong vibrations in the vehicle, screwed busbars can detach themselves. The flexible cables with the plug connections are able to compensate for these vibrations.
We need your consent This YouTube video is provided by Google*. If you load the video, your data - including your IP address - is transmitted to Google and may be stored and processed by Google inter alia in the USA. We have no influence over further data processing by Google. By clicking on "Accept", you consent to the transmission of data to Google for this video in accordance with Art. 6 (1) (a) GDPR and at the same time expressly consent to the transfer of data to the USA in accordance with Art. 49 (1) (a) GDPR. If you no longer wish to consent to each YouTube video individually in the future and wish to be able to load the videos without this blocker, you can also select "Always accept YouTube" and thereby consent to the associated data transmissions and transfers to Google and to the USA for all other YouTube videos which you open on our website in the future. Please note that, in the opinion of the European Court of Justice, there does not currently exist an adequate level of data protection in line with EU standards in the USA, and at present we cannot provide suitable safeguards to protect your data and offset this shortcoming. Possible risks to you of data transfer to the USA are that access by state authorities cannot be excluded and that your data could be processed for reasons of national security, criminal prosecution or for other purposes in the public interest of the USA, possibly without you being informed separately and without enforceable rights and effective means of redress being available to you. You can withdraw consent that you have given at any time with future effect via the settings. For further information, please see our Data Protection Declaration and Google's Privacy Policy. *Google Ireland Limited, Gordon House, Barrow Street, Dublin 4, Irland; Mutterunternehmen: Google LLC, 1600 Amphitheatre Parkway, Mountain View, CA 94043, USA

Video E-Mobility solutions by Liebherr

Automated plugging of high voltage battery module connectors

Challenge: the automation of soft parts

For these reasons, there is growing interest from manufacturers in pluggable connections. However, since the automated assembly of soft components presents an engineering challenge, this has till now still been carried out manually. This can cause a bottleneck in production if batch sizes increase. The problem is that the parts have low resistance against shape changes. They already become very highly deformed as a result of even small stresses, such as their own weight. These changes in shape are often a rejection criterion for the automation of handling or assembly processes.

Innovative automation solution by Liebherr

Liebherr has developed a unique solution for this to enable the automated, process reliable, plugging of module connections. Two cooperating robots each grip one end of the cable and carry out the plugging process synchronously with temporally and geometrically coordinated movements. Using a 2D camera, the robot detects the real position of the slots, thus enabling positioning tolerances to be compensated. The actual, mechanical plugging process is performed using a pneumatic cylinder. A spring assembly limits the force transfer to the module, plug and plug lock to secure the position (CPA). Finally, process reliable monitoring is performed by a stop position sensor. Liebherr can also solve the laying of the cables in the desired position and geometry using suitable cable bend grips.

KOSTAL Kontakt Systeme GmbH

Sector:
Development, production and distribution of plug systems for the automotive industry

Company size:
1,400 employees

Founded:
1993

Company headquarters:
Lüdenscheid, Germany

Sites:
9 sites on three continents: Dresden (Germany), Goldthorpe (Rotherham, Great Britain), Gyancourt (France), Jince (Czech Republic), Turin (Italy), Rochester Hills (Michigan, USA), Shanghai (China), Seoul (Korea)

Turnover:
approx. €3 billion

Website:
www.kostal-kontakt-systeme.com/en-us/

This may be of interest to you

Evotion 2021

Evotion 2021

Discover further interesting stories about gear technology and automation systems.

Our stories
Downloads

Downloads

You can download all customer magazines in PDF format.

Downloads
Product area automationsystems

Product area automationsystems

Here you can find an overview about of products and services.

Automation systems