High-Voltage Wiring for 400- and 800-Volt Vehicle Electrical Systems

With every kilowatt of charging power, the demands on the connection increase. Cross-sectional area, shielding, contact resistance, and temperature behavior are all interrelated, and every safety margin adds weight. KE Elektronik manufactures high-voltage and high-current cable assemblies with Amphenol contact systems that were developed specifically for these applications. This results in more compact high-voltage connectors with the same power density.

The assembly of high-voltage cables leaves no room for error. 360° shielding inspection and crimp force are measured and documented by the system—not just checked on a random basis. We coordinate touch protection, locking mechanisms, and HVIL contacts with you as early as the design phase.

Whether it's a PDU connection, a pigtail on the high-voltage battery, or a connection to the electric axle: We build the wiring harness according to your specifications, including the integration of cable channels, cable clamps, and labeling for traceability. 

Vehicle wiring harness development doesn’t end with the CAD model. Anyone designing high-voltage cables must know how they can be routed and installed at the factory. We require a 100% end-of-line test for the wiring harnesses. We identify critical areas early on through calculations and simulations, build prototypes in-house, and feed insights from mass production back into the design process.

Automated manufacturing cells with process-integrated monitoring are available for high-volume production. Injection molding with clamping forces ranging from 40 to 200 metric tons, wire harness assembly in a single pass, and electrical testing on the fly. As specialists in wire processing, plastics technology, and assembly and connection technology, we supply high-voltage components and complete wiring harnesses from a single source.