Issue: Jul 2017


Future-proof technology for high-voltage charging cables



by Nick Palmen

High-tech electronic cable design is needed for both electric and combustion-powered vehicles.

With electric vehicles cables are carrying higher and higher voltages as manufacturers move to high-speed charging and electrification is extended to commercial and other heavy machinery. High voltages create electronic fields which can also disrupt vehicle electronics.

Under the bonnet of the typical internal combustion engine one finds a growing array of sensors, with components such as wiring expected to perform over the lifetime of the vehicle at higher operating temperatures and with restricted space. One of the first companies to meet the requirements of the automotive industry for a complete range of shielded power cables is, HUBER+SUHNER.

In compliance with ISO 6722, the company now offers the intermediate cross sections 8, 12, 20, 30, 40 and 60 mm, in addition to the standard sizes.

According to the company its shielded RADOX®power cables are ideal for high voltage applications in hybrid and electric vehicles.

Because particularly high currents flow in these vehicles, electronic shielding is needed to prevent the disruption of sensors and electronics in the vehicle space and surroundings. The entire product family is also available in unshielded versions.

Automotive Industries (AI) asked Marc-Andre Beck, LF Market Manager Industry at HUBER+SUHNER what is the range of RADOX® cables and complete cable systems for the automotive industry.

Beck: HUBER+SUHNER provide a wide range of cables and cable systems that feature the leading RADOX® technology.

This includes single core cables, sensor cables, data bus cables, battery cables, high voltage cables and the unique anti-capillary cables.

AI: What is RADOX?

Beck: Developed in-house at HUBER +SUHNER,

“RADOX” stands for "radiation X-linked”, and describes the process of crosslinking thermoplastic polymers by means of electron beams.

The cables are designed and manufactured in accordance with international standards, as well as customer-specific requirements to achieve notable improvements in the thermal, mechanical and chemical properties of the cable insulation material.

AI: What are the advantages of the RADOX material?

Beck: There are several advantages of using the RADOX material. The cables do not melt, possess better abrasion resistance and greater cut resistance than conventional cables and, even with thinner insulation, are much more resistant to various environmental factors.

AI: How does your extensive experience help in the development and manufacture of dedicated cable harnesses and demanding cable systems?

Beck: The development of complex and customized cable systems for the automotive industry is based on years of experience in working with leading global vehicle manufacturers. The assistance that HUBER+SUHNER can provide in manufacturing ranges from delivering single components to development and integration of complete high voltage systems, including the design of cable assemblies and connection systems (RACS), the harness routing and high voltage distribution units (HVDU).

AI: Do you offer turnkey connectivity solutions from the planning stage?

Beck: HUBER+SUHNER is a full systems provider. We offer our customers services throughout all stages of their projects. This includes services such as R&D, engineering and prototyping for the planning stage, as well as testing and validation, and the support of the implementation process on the final stages of a project.

This demonstrates that HUBER+SUHNER is a specialist in the development of customer specific solutions from beginning to end.

AI: How does the new RADOX® High Power Charging System multiply the power throughput of a charging cable?

Beck: The RADOX High Power charging cables include a heat transport mechanism, which eliminates heat and hotspots through convection. This is a very efficient mechanism, and enables the effective transport of high currents through very thin and flexible cables.

AI: What makes it different?

Beck: As opposed to conventional cables that are only able to dissipate heat through radiation, the RADOX high power charging system allows for active cooling, which is essential to avoid overheating and hotspots, ensuring a convenient handling and very short charging times.

AI: What connector interface does the new system come with?

Beck: The HUBER+SUHNER RADOX HPC system enables high power charging with the internationally standardized interface Combined Charging System (CCS) – CCS-2 interface for the European market and CCS-1 for the US/Canadian market.

AI: Can the new system be individually customer designed?

Beck: The RADOX HPC system can be personalized to any customer-specific brand or logo. The color of the cab may also be changed on customer request.

AI: What are the main features and benefits?

Beck: We have essentially improved our customers’ experience by putting super-fast charging within reach. The

RADOX HPC system has the ability to charge up to 80% in under

15 minutes. With ergonomic design and low installation costs, this future oriented system is simple and easy to use. The aim of this system is to make high-power charging more convenient than refueling your car with gasoline.

AI: Is the new system suitable for all electric vehicles and trucks?

Beck: The future-proof HUBER+SUHNER RADOX HPC technology is suitable and should be considered as an essential addition for all electric vehicles, specialized vehicles, construction vehicles and trucks with big battery packs



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Automotive Industries
THE FUTURE OF CONNECTED AND ELECTRIFIED POWERTRAINS IN VEHICLES By TE Connectivity

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