HITACHIHITACHIPower Harness For Power Harness For

Hybrid Electric Vehicle Hybrid Electric Vehicle

Hitachi Cable, Ltd.

Industrial System DepartmentApril, 2001

CONTENTS(1)CONTENTS(1)1. Corporate Profile1. Corporate Profile

1.1 Company Outline1.2 Sales 1.3 Sales for Automotive Industry1.4 A Brief History of Automotive Business1.5 Major Customers

2. Worldwide Facilities 2. Worldwide Facilities 2.1 Japan 2.2 International

3. Condition of use3. Condition of use4. Selection of cable4. Selection of cable

4.1 The Point of selection 4.2 The basis of data4.3 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 sec4.6 700A heat rise for 20 sec4.7 Conclusion4.8 Ampacity4.9 Insulation options

CONTENTS(2)CONTENTS(2)

4.10 Arc Experiment results4.11 EMI Simulation results4.12 Benefits of HEV cable

5. 3 pole connector cable concept6. Coaxial battery cable concept

6.1 Coaxial battery cable connector concept

7. Brake-By-Wire 7.1 Advantages of Hitachi BBW Cable and connector7.2 Connector concept7.3 Cable types

1.1 Company Outline 1.1 Company Outline

EstablishmentEstablishment 19561956 Capital Capital 26 billion yen26 billion yen Sales Sales 320 billion yen320 billion yen Employees Employees 66006600 Primary ProductsPrimary Products Wire & Cable, Copper Products,Wire & Cable, Copper Products, Electronic Material, Components, Electronic Material, Components,

and Rubber Products and Rubber Products Sales Office Sales Office Tokyo Head-office, and 14 Tokyo Head-office, and 14

branch officesbranch offices Products Facilities Products Facilities Six in Ibaraki, and one in AomoriSix in Ibaraki, and one in Aomori

1. Corporate Profile

Total SalesApprox.30billion yen/Month

1.2 Sales (1998)1.2 Sales (1998)

Power Cables

Construction Industry

Automotive 　

Telecommunication Cables

14%

5%

Electric & Machine Industry

24%

4%

15%

Domestic others

17%

Export

21%

Approx. 2 Billion yen/month W/W

1.3 Sales for Automotive 1.3 Sales for Automotive

58%

18%

12%

6% 2% 2% 2%

Brake & PAS Hose Assembly

AV Wire ＆ Cable

Magnet Wire, Clad Materials

Copper Strip, Fin, Tube

ABS (Sensor & Cable)

FFC (Flexible Flat Cable)

Others

1969 Awarded Nissan Brake Hose Business.1969 Awarded Nissan Brake Hose Business.1971 Started Production of Automotive Wire & Cable.1971 Started Production of Automotive Wire & Cable.1973 Founded “Kyohritsu Hiparts Ltd.”1973 Founded “Kyohritsu Hiparts Ltd.”

Awarded Mazda Brake Hose Business.Awarded Mazda Brake Hose Business.1975 Awarded Isuzu Brake Hose Business.1975 Awarded Isuzu Brake Hose Business.1980 Awarded GM(OPEL) Brake Hose Business.1980 Awarded GM(OPEL) Brake Hose Business.1987 Awarded Ford Brake Hose Business.1987 Awarded Ford Brake Hose Business.

Established Hose & Assembly Production Established Hose & Assembly Production in The in The

USA(HCI).USA(HCI).1991 Awarded Toyota Brake Hose Business. Started Production of ABS Cable.

1.4 A Brief Record for Automotive Business(1)1.4 A Brief Record for Automotive Business(1)

1992 Awarded Honda Brake Hose Business.1992 Awarded Honda Brake Hose Business.1994 Established Hose Assembly Company in Mexico(HCQ) 1994 Established Hose Assembly Company in Mexico(HCQ) 1997 Started Production of Halogen-Free-Cable.1997 Started Production of Halogen-Free-Cable.1998 Started Production of “JAMCAT”.1998 Started Production of “JAMCAT”. Started Production of ABS Sensor.Started Production of ABS Sensor.1999 Established Hose Assembly & Cable Production in 1999 Established Hose Assembly & Cable Production in Philippines(HCP)Philippines(HCP) Started Assembly of Brake Hose for Motorcycles.Started Assembly of Brake Hose for Motorcycles.20002000 Established Established Hose Assembly in Europe(HCUK). Hose Assembly in Europe(HCUK). Started Production of HEV Cable of TOYOTA PRIUS.Started Production of HEV Cable of TOYOTA PRIUS.

1.4 A Brief Record for Automotive 1.4 A Brief Record for Automotive Business(2)Business(2)

Vehicle Manufacturers FORD, HONDA, ISUZU, MAZDA, NISSAN, FORD, HONDA, ISUZU, MAZDA, NISSAN,

OPEL, ROVER, SAAB, SUBARU, TOYOTA, OPEL, ROVER, SAAB, SUBARU, TOYOTA,

VAUXALL etc.VAUXALL etc.

Automotive Components Manufacturers ASMO, ALPS ELECTRONIC, DENSO, HITACHI,ASMO, ALPS ELECTRONIC, DENSO, HITACHI,

JIDECO, KOYO SEIKO ,KYOURITSU HIPARTS,JIDECO, KOYO SEIKO ,KYOURITSU HIPARTS,

MITSUBA, SHOWA, TOKICO, UNISIA JECS, MITSUBA, SHOWA, TOKICO, UNISIA JECS,

ZEXEL, etc.ZEXEL, etc.

1.5 Major Customers1.5 Major Customers

2.1 Japan2.1 JapanDensen Works Hitaka Works

Toyoura Works Tsuchiura Works

Location:Hitachi

Rubber Hose

ABS Sensor

Location:Hitachi

Magnet Wires for Motor

Clad Materials

FFC

Location:Hitachi

Wire & Cables

AV Wires

JAMCAT®

Location:Tsuchiura

Commutating Materials

Copper Products for Heater

Copper Foils

2. Production Facilities

HCI

HCP HCQ

HCL

2.2 International2.2 International

International Operation

HCI : Hitachi Cable Indiana

HCQ : Hitachi Cable Queretaro

HCL : Hitachi Cable Limited

HCP : Hitachi Cable Philippines

HCUK : Hitachi Cable UK

HCUK

3. Condition of use3. Condition of useVoltage : 42V

Current (Peak) : 500A-60sec.

Current (Normal) : 175A(RMS)

Environment Temperature : Max 120 C

4. Selection of cable4. 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.

Time(sec.)Current Description

60 120 180

Experiment 14.2 23.7 32.1100 A

Calculation 15.9 29.0 39.7

Experiment 19.8 34.8 45.2120 A

Calculation 22.9 41.7 57.2

Experiment 32.8 56.5 74.9150 A

Calculation 35.8 65.2 89.4

Rise temperature (deg C) Current

Experiment Calculation 30 A 7.3 8.1 50 A 17.5 22.5 65 A 28.7 38.0

Table 1. Rise temperature of normal current

Table 2. Rise temperature of short time current

4.3 The rise in conductor temperature(Normal current : 175A)

0

10

20

30

40

50

60

70

80

90

100

0 600 1200 1800 2400 3000 3600Time(sec.)

Ris

e te

mpe

ratu

re (

deg

C)

20 mm230 mm240 mm250 mm2

4.4 The rise in conductor temperature(Peak current : 500A)

0

50

100

150

200

0 30 60 90 120 150 180Time(sec.)

Ris

e te

mp

erat

ure

(deg

C)

20 mm230 mm240 mm250 mm2

4.5 550A Peak for 3sec. 4.5 550A Peak for 3sec.

0

5

10

15

20

0 1 2 3 4 5 6 7 8 9 10Time(sec.)

Ris

e te

mp

erat

ure

( )

30 mm2

40 mm2

4.6 700A peak for 20sec.4.6 700A peak for 20sec.

0

5

10

15

20

25

30

0 5 10 15 20 25 30Time(sec.)

Ris

e te

mpe

ratu

re(

)

30 mm2

40 mm2

50 mm2

4.7 Conclusion4.7 ConclusionConductor size : 40mm2

Material of insulation : Fluonlex®

Specification of cableSpecification of cable

Item Unit Standard Value

No. of core － 1Section area mm2 40Construction No.／mm 19/26/0.32ConductorDiameter(Approx.) mm 9.5Thickness mm 1.4

InsulationDiameter mm 12.4Construction End/Carrier/mm 8/24/0.18Shield

Braid Thickness mm 0.45Sheath thickness mm 1.6Overall diameter(Appox.) mm 16.5Conductor resistance(20) Ohm/km 0.48

Conductor

Insulation (Fluonlex)

Braid shield

Sheath(PVC)

4.8 Ampacity 4.8 Ampacity

0

100

200

300

0 50 100 150Temperature(C)

Am

paci

ty(A

)

XLPE 30sq

XLPE 40sq

FLOUNLEX 30sq

FLOUNLEX 40sq

4.9 Insulation material option4.9 Insulation material option

Item XLPE FLOUNLEX Maximum

Temperature 120°C 150°C

Flexibility X XX Oil resistance XX XXX Heat resistance XX XXX Ampacity of 40mm2

cable at 80? 140A (100)

177A (126)

Cost XXX XX

XXX - Excellent XX - Good X - Fair

4.10 ARC Experiment Results4.10 ARC Experiment ResultsRate ： 400mm/min

With insulation on Pin contact tipRate ： 400mm/min

Without insulation on Pin contact tip

Voltage ： 48VCurrent ： 30A

Rate ： 50mm/minWith insulation on Pin contact tip

Rate ： 50mm/minWithout insulation on Pin contact tip

4.11 Measurement by Magnetic close sensor4.11 Measurement by Magnetic close sensor

Frequency: １ＭＨｚ

（ 1 ） With Shield Case

SpectrumAnalyzerShield Box

（ Iron ）

Table

50Ω

CONNECTOR CABLE

Magnetic field

Coil

PrincipleAppearance

Circuit

（ 2 ） Without Shield Case

SpectrumAnalyzer

4.12 Benefits of Hitachi Cable’s HEV Cable4.12 Benefits of Hitachi Cable’s 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.

5. 3 Pole connector cable concept5. 3 Pole connector cable conceptCable Specification

---- 1

Cross section area mm2 40

Construction No./mm 19/26/0.32TA

Diameter mm 9.5

Thickness mm 1.4

Diameter mm 12.3

mm 26.8

ShieldBraid

Thickness mm 0.45

mm 1.6

mm 30.9

Ω/km 1.42

Kg/km 1,800

Item Unit Specification Value

No. of core

Conductor

Insulation

Cabling diameter

Construction

Conductor resistance (20°C)Estimate weight

No./No./mm 15/24/0.18TA

Sheath thickness

Overall diameter (Approx.)

Cross section

6. Coaxial battery cable concept6. Coaxial battery cable concept Item Unit Specification value

No. of core ? 1 Cross section area mm2 40 Construction No./mm 19/26/0.32TA Conductor Diameter mm 9.50 Thickness mm 1.10

Insulation Diameter mm 11.7 Construction No./No./mm 26/19/0.32TA Wrapping

Shield Thickness mm 1.60 Sheath thickness mm 1.60 Overall diameter (Aprox.) mm 18.10 Conductor resistance (20°C) Ω/km 1.39 Estimate weight kg/km 980

Inner conductor

InsulationOuter wrapping conductor

Sheath

Cross section

Cable specification

6.1 Coaxial cable & connector concept6.1 Coaxial cable & connector concept Item Unit Specification value

No. of core － 1Cross section area mm2 40Construction No./mm 19/26/0.32TAConductorDiameter mm 9.50Thickness mm 1.10

InsulationDiameter mm 11.7Construction No./No./mm 26/19/0.32TAWrapping

Shield Thickness mm 1.60Sheath thickness mm 1.60Overall diameter (Aprox.) mm 18.10Conductor resistance (20) Ω/km 1.39Estimate weight kg/km 980

Inner conductor

InsulationOuter wrapping conductor

Sheath

Cross section

Cable specification

Connector Concept: CoaxialDevelopment item1. Insert MoldInsert molding is difficult regarding Pin-Contact, two Ring spacers, and especially Socket Contact.2. Mating ForceMating force of the connector is expected to be largedue to a large number of contact points.3. Contact Method of Shield Wire to The CaseIt is not decided how to contact shield wire(external side)to the case. It is necessary to find a good method.4. Temperature RiseTemperature is expected to largely increase because of big current with dual structure. It is necessary to select a proper material.

Cross section

7.0 Brake-By-Wire Cable and 7.0 Brake-By-Wire Cable and ConnectorConnector

7.1 Brake-By-Wire Cable and 7.1 Brake-By-Wire Cable and ConnectorConnector

AdvantagesCable

• 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

7.2 BBW Connector Concept7.2 BBW Connector Concept

7.3 Brake-By-Wire Cable currently 7.3 Brake-By-Wire Cable currently under developmentunder development

Item Type A Type B Type CNo. 1 2 3 4 5

Construction 5x0.2mm2+2x2mm2 2x0.2mm2+2x2mm2 3Px0.2mm2+2x2mm2 4x0.5mm2 4Px0.2mm2

Shield Braid (mm) 0.12 0.1 0.1 0.12 0.08Material Insulation SheathMax overall diameter (mm) 8.6 9.0 10.5 7.2 10.3Characteristics

High voltage use (MAX:350V)

Specification of BBW Cable

Power lines and shielded Signal lines in one cable

42V use

Power line and Signal line in separate cables

Type D

Uniflammable Cross linked PolyurethanePolyurethane